Plasma arc cutting system

Transcripción

COV_OM_805160.qxp:COV_OM_805160
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Plasma arc cutting system
Operator Manual – 805160
Revision 2
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Register your new Hypertherm system
Register your product on-line at www.hypertherm.com/registration for
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For your records
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powermax30
Operator Manual
(P/N 805160)
Revision 2 – November 2009
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
email:[email protected]
© Copyright 2009 Hypertherm, Inc.
All Rights Reserved
Hypertherm and Powermax are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries.
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Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[email protected] (Customer Service Email)
Hypertherm Automation
5 Technology Drive, Suite 300
West Lebanon, NH 03784 USA
603-298-7970 Tel
603-298-7977 Fax
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit A, 5th Floor, Careri Building
432 West Huai Hai Road
Shanghai, 200052
PR China
86-21 5258 3330/1 Tel
86-21 5258 3332 Fax
7/1/09
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
801 Samty Will Building
2-40 Miyahara 1-Chome,
Yodogawa-ku, Osaka
532-0003, Japan
81 6 6170 2020 Tel
81 6 6170 2015 Fax
Hypertherm Brasil Ltda.
Avenida Doutor Renato de
Andrade Maia 350
Parque Renato Maia
CEP 07114-000
Guarulhos, SP Brasil
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
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Page i
ELECTROMAGNETIC COMPATIBILITY (EMC)
EMC Introduction
Hypertherm’s CE-marked equipment is built in
compliance with standard EN60974-10. The
equipment should be installed and used in
accordance with the information below to
achieve electromagnetic compatibility.
The limits required by EN60974-10 may not
be adequate to completely eliminate interference when the affected equipment is in close
proximity or has a high degree of sensitivity.
In such cases it may be necessary to use other
measures to further reduce interference.
This cutting equipment is designed for use
only in an industrial environment.
Installation and use
The user is responsible for installing and
using the plasma equipment according to the
manufacturer’s instructions. If electromagnetic
disturbances are detected then it shall be the
responsibility of the user to resolve the
situation with the technical assistance of the
manufacturer. In some cases this remedial
action may be as simple as earthing the
cutting circuit, see Earthing of Workpiece.
In other cases it could involve constructing an
electromagnetic screen enclosing the power
source and the work complete with associated
input filters. In all cases electromagnetic
disturbances must be reduced to the point
where they are no longer troublesome.
Assessment of area
Before installing the equipment the user shall
make an assessment of potential electromagnetic problems in the surrounding area.
The following shall be taken into account:
a. Other supply cables, control cables,
signalling and telephone cables; above,
below and adjacent to the cutting equipment.
Hypertherm
b. Radio and television transmitters and
receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example
guarding of industrial equipment.
e. Health of the people around, for example the
use of pacemakers and hearing aids.
f. Equipment used for calibration or
measurement.
g. Immunity of other equipment in the
environment. User shall ensure that other
equipment being used in the environment is
compatible. This may require additional
protection measures.
h. Time of day that cutting or other activities
are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking
place. The surrounding area may extend
beyond the boundaries of the premises.
Methods of reducing
emissions
Mains supply
Cutting equipment must be connected to the
mains supply according to the manufacturer’s
recommendations. If interference occurs, it may
be necessary to take additional precautions
such as filtering of the mains supply.
Consideration should be given to shielding the
supply cable of permanently installed cutting
equipment, in metallic conduit or equivalent.
Shielding should be electrically continuous
throughout its length. The shielding should
be connected to the cutting mains supply so
that good electrical contact is maintained
between the conduit and the cutting power
source enclosure.
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Page ii
ELECTROMAGNETIC COMPATIBILITY (EMC)
Maintenance of cutting equipment
The cutting equipment must be routinely
maintained according to the manufacturer’s
recommendations. All access and service doors
and covers should be closed and properly
fastened when the cutting equipment is in
operation. The cutting equipment should not be
modified in any way except for those changes
and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc
striking and stabilizing devices should be
adjusted and maintained according to the
manufacturer’s recommendations.
Cutting cables
The cutting cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic components in the
cutting installation and adjacent to it should be
considered. However, metallic components
bonded to the workpiece will increase the risk
that the operator could receive a shock by
touching these metallic components and the
electrode (nozzle for laser heads) at the same
time. The operator should be insulated from all
such bonded metallic components.
workpiece to earth should be made by a direct
connection to the workpiece, but in some
countries where direct connection is not
permitted, the bonding should be achieved by
suitable capacitances selected according to
national regulations.
Note: the cutting circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be
authorized by a person who is competent to
assess whether the changes will increase the
risk of injury, for example, by allowing parallel
cutting current return paths which may damage
the earth circuits of other equipment. Further
guidance is given in IEC/ TS 62081 Arc
Welding Equipment Installation and Use.
Screening and shielding
Selective screening and shielding of other
cables and equipment in the surrounding area
may alleviate problems of interference.
Screening of the entire plasma cutting
installation may be considered for special
applications.
Earthing of workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of its size and position, for example,
ship’s hull or building steelwork, a connection
bonding the workpiece to earth may reduce
emissions in some, but not all instances.
Care should be taken to prevent the earthing
of the workpiece increasing the risk of injury to
users, or damage to other electrical equipment.
Where necessary, the connection of the
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Hypertherm
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Page iii
WARRANTY
Attention
Genuine Hypertherm parts are the factoryrecommended replacement parts for your
Hypertherm system. Any damage caused by the
use of other than genuine Hypertherm parts may
not be covered by the Hypertherm warranty.
You are responsible for the safe use of the
Product. Hypertherm does not and cannot make
any guarantee or warranty regarding the safe
use of the Product in your environment.
General
Hypertherm, Inc. warrants that its Products shall
be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with
respect to the power supply within a period of
two (2) years from the date of its delivery to you,
with the exception of Powermax brand power
supplies, which shall be within a period of three
(3) years from the date of delivery to you, and
(ii) with respect to the torch and leads within a
period of one (1) year from its date of delivery to
you, and with respect to torch lifter assemblies
within a period of one (1) year from its date of
delivery to you, and with respect to laser heads
within a period of one (1) year from its date of
delivery to you. This warranty shall not apply to
any Powermax brand power supplies that have
been used with phase converters. In addition,
Hypertherm does not warranty systems that
have been damaged as a result of poor power
quality, whether from phase converters or
incoming line power. This warranty shall not
apply to any Product which has been incorrectly
installed, modified, or otherwise damaged.
Hypertherm, at its sole option, shall repair,
replace, or adjust, free of charge, any defective
Products covered by this warranty which shall
be returned with Hypertherm’s prior
authorization (which shall not be unreasonably
withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire,
or to an authorized Hypertherm repair facility, all
Hypertherm
costs, insurance and freight prepaid.
Hypertherm shall not be liable for any repairs,
replacement, or adjustments of Products
covered by this warranty, except those made
pursuant to this paragraph or with Hypertherm’s
prior written consent. The warranty above is
exclusive and is in lieu of all other
warranties, express, implied, statutory, or
otherwise with respect to the Products or
as to the results which may be obtained
therefrom, and all implied warranties or
conditions of quality or of merchantability
or fitness for a particular purpose or
against infringement. The foregoing shall
constitute the sole and exclusive remedy
for any breach by Hypertherm of its
warranty. Distributors/OEMs may offer different
or additional warranties, but Distributors/OEMs
are not authorized to give any additional
warranty protection to you or make any
representation to you purporting to be binding
upon Hypertherm.
Certification test marks
Certified products are identified by one or more
certification test marks from accredited testing
laboratories. The certification test marks are
located on or near the data plate. Each
certification test mark means that the product
and its safety-critical components conform to
the relevant national safety standards as
reviewed by that testing laboratory. Hypertherm
places a certification test mark on its products
only after that product is manufactured with
safety-critical components that have been
authorized by the accredited testing laboratory.
Once the product has left the Hypertherm
factory, the certification test marks are
invalidated if any of the following occurs:
• The product is significantly modified
in a manner that creates a hazard or
non-conformance.
• Safety-critical components are replaced with
unauthorized spare parts.
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WARRANTY
• Any unauthorized assembly or accessory that
uses or generates a hazardous voltage is
added.
• There is any tampering with a safety circuit or
other feature that is designed into the product
as part of the certification.
CE marking constitutes a manufacturer’s
declaration of conformity to applicable European
directives and standards. Only those versions of
Hypertherm products with a CE Marking located
on or near the data plate have been tested for
compliance with the European Low Voltage
Directive and the European EMC Directive.
EMC filters needed to comply with the European
EMC Directive are incorporated within versions
of the power supply with a CE Marking.
Differences in National Standards
Differences in standards include, but are not
limited to:
•
•
•
•
Voltages
Plug and cord ratings
Language requirements
Electromagnetic compatibility requirements
These differences in national standards may
make it impossible or impractical for all
certification test marks to be placed on the
same version of a product. For example, the
CSA versions of Hypertherm’s products do not
comply with European EMC requirements and
they do not have a CE marking on the data
plate.
Countries that require CE marking or have
compulsory EMC regulations must use CE
versions of Hypertherm products with the CE
marking on the data plate. These include:
•
•
•
•
Australia
New Zealand
Countries in the European Union
Russia
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It is important that the product and its
certification test mark be suitable for the enduse installation site. When Hypertherm
products are shipped to one country for export
to another country, the product must be
configured and certified properly for the enduse site.
Higher-level systems
When a system integrator adds additional
equipment; such as cutting tables, motor drives,
motion controllers or robots; to a Hypertherm
plasma cutting system, the combined system
may be considered a higher-level system. A
higher-level system with hazardous moving parts
may constitute industrial machinery or robotic
equipment, in which case the OEM or end-use
customer may be subject to additional
regulations and standards than those relevant to
the plasma cutting system as manufactured by
Hypertherm.
It is the responsibility of the end-use customer
and the OEM to perform a risk assessment for
the higher-level system and to provide
protection against hazardous moving parts.
Unless the higher-level system is certified when
the OEM incorporates Hypertherm products
into it, the installation also may be subject to
approval by local authorities. Seek advice from
legal counsel and local regulatory experts if
uncertain about compliance.
External interconnecting cables between
component parts of the higher level system
must be suitable for contaminants and
movement as required by the final end-use
installation site. When the external interconnecting cables are subject to oil, dust, or
water contaminants, hard usage ratings may be
required. When external interconnecting cables
are subject to continuous movement, constant
flexing ratings may be required. It is the
responsibility of the end-use customer or the
OEM to ensure the cables are suitable for the
application. Since there are differences in the
Hypertherm
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TABLE OF CONTENTS
Electromagnetic compatibility................................................................................................................................i
Warranty....................................................................................................................................................................iii
Section 1 Safety
Recognize safety information ...........................................................................................................................1-2
Follow safety instructions..................................................................................................................................1-2
Cutting can cause fire or explosion ................................................................................................................1-2
Electric shock can kill.........................................................................................................................................1-3
Static electricity can damage circuit boards ................................................................................................1-3
Toxic fumes can cause injury or death............................................................................................................1-4
A plasma arc can cause injury and burns......................................................................................................1-5
Arc rays can burn eyes and skin......................................................................................................................1-5
Grounding safety.................................................................................................................................................1-6
Compressed gas equipment safety................................................................................................................1-6
Gas cylinders can explode if damaged..........................................................................................................1-6
Noise can damage hearing ...............................................................................................................................1-7
Pacemaker and hearing aid operation............................................................................................................1-7
A plasma arc can damage frozen pipes.........................................................................................................1-7
Additional safety information.............................................................................................................................1-7
Warning labels .....................................................................................................................................................1-8
Section 1a Sécurité
Identifier les consignes de sécurité ..............................................................................................................1a-2
Suivre les instructions de sécurité ................................................................................................................1a-2
Danger Avertissement Précaution ..............................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................1a-2
Les chocs électriques peuvent être fatals ..................................................................................................1a-3
Le coupage peut produire des vapeurs toxiques ......................................................................................1a-3
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................1a-4
Les rayons de l’arc peuvent brûler les yeux et la peau.............................................................................1a-4
Mise à la masse et à la terre...........................................................................................................................1a-4
Sécurité des bouteilles de gaz comprimé...................................................................................................1a-5
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ..........................................1a-5
Le bruit peut provoquer des problèmes auditifs........................................................................................1a-5
Pacemakers et prothèses auditives..............................................................................................................1a-5
Un arc plasma peut endommager les tuyaux gelés ..................................................................................1a-5
Étiquette de sécurité ........................................................................................................................................1a-6
Section 1b Seguridad
Reconocimiento de información de seguridad ..........................................................................................1b-2
Siga las instrucciones de seguridad ............................................................................................................1b-2
Los cortes pueden provocar incendios o explosiones ............................................................................1b-2
El choque eléctrico puede provocar la muerte..........................................................................................1b-3
Electricidad estática puede dañar tablillas de circuito ............................................................................1b-3
Humos tóxicos pueden causar lesiones o muerte....................................................................................1b-4
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TABLE OF CONTENTS
El arco de plasma puede causar lesiones y quemaduras.......................................................................1b-5
Los rayos del arco pueden producir quemaduras en los ojos y en la piel ..........................................1b-5
Seguridad de toma a tierra.............................................................................................................................1b-6
Seguridad de los equipos de gas comprimido..........................................................................................1b-6
Los cilindros de gas pueden explotar si están dañados .........................................................................1b-6
El ruido puede deteriorar la audición ...........................................................................................................1b-7
Operación de marcapasos y de audífonos.................................................................................................1b-7
Un arco plasma puede dañar tubos congelados ......................................................................................1b-7
Etiquetas de advertencia ................................................................................................................................1b-8
Section 2 Specifications
System description .............................................................................................................................................2-2
Power supply dimensions and weight ..........................................................................................................2-2
Power supply ratings..........................................................................................................................................2-3
Torch dimensions ................................................................................................................................................2-4
T30v torch ratings...............................................................................................................................................2-4
Symbols and markings.......................................................................................................................................2-5
mark ......................................................................................................................................................2-5
CE mark ......................................................................................................................................................2-5
IEC symbols...............................................................................................................................................2-5
Section 3 Setup
Unpack the Powermax30 ..................................................................................................................................3-2
Claims .........................................................................................................................................................3-2
Contents .....................................................................................................................................................3-2
Position the power supply.................................................................................................................................3-3
Voltage configurations .......................................................................................................................................3-3
Requirements for grounding.............................................................................................................................3-3
Power cord considerations...............................................................................................................................3-4
Power cord and plugs for CSA power supplies ...............................................................................3-4
Power cord for CE power supplies ......................................................................................................3-5
Extension cord recommendations ........................................................................................................3-6
Generator recommendations .................................................................................................................3-6
Gas supply............................................................................................................................................................3-7
Connection.................................................................................................................................................3-7
Additional gas filtration............................................................................................................................3-8
Section 4 Operation
Controls and indicators .....................................................................................................................................4-2
Front controls and LEDs.........................................................................................................................4-2
Rear controls .............................................................................................................................................4-2
Install the consumables .....................................................................................................................................4-3
Attach the work clamp .......................................................................................................................................4-4
Power ON the system........................................................................................................................................4-4
Hand torch operation .........................................................................................................................................4-6
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Safety trigger operation ..........................................................................................................................4-6
Hand torch cutting hints..........................................................................................................................4-7
To start a cut from the edge of the workpiece...................................................................................4-8
To pierce a workpiece..............................................................................................................................4-9
Cut chart.............................................................................................................................................................4-10
Duty cycle and overheating............................................................................................................................4-11
Common cutting faults ....................................................................................................................................4-11
Section 5 Maintenance and parts
Routine maintenance..........................................................................................................................................5-2
Inspect the consumables ..................................................................................................................................5-3
Basic troubleshooting ........................................................................................................................................5-4
Repairs...................................................................................................................................................................5-7
Remove and replace the cover and Nomex® barrier .......................................................................5-7
Remove an endcap ..................................................................................................................................5-9
Disconnect the torch lead....................................................................................................................5-11
Replace the work lead ..........................................................................................................................5-13
Replace the power cord (CSA)..........................................................................................................5-15
Replace the power cord (CE) .............................................................................................................5-17
Replace the air filter element...............................................................................................................5-19
Replacement and accessory parts ...............................................................................................................5-20
Power cords and adapters...................................................................................................................5-20
Accessory parts......................................................................................................................................5-20
T30v hand torch assembly ..................................................................................................................5-21
Consumables ..........................................................................................................................................5-21
Filter regulator.........................................................................................................................................5-22
Work clamp .............................................................................................................................................5-22
Powermax30 labels ...............................................................................................................................5-23
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viii
Section 1
SAFETY
In this section:
Recognize safety information ...........................................................................................................................1-2
Follow safety instructions..................................................................................................................................1-2
Cutting can cause fire or explosion ................................................................................................................1-2
Electric shock can kill.........................................................................................................................................1-3
Static electricity can damage circuit boards ................................................................................................1-3
Toxic fumes can cause injury or death............................................................................................................1-4
A plasma arc can cause injury and burns......................................................................................................1-5
Arc rays can burn eyes and skin......................................................................................................................1-5
Grounding safety.................................................................................................................................................1-6
Compressed gas equipment safety................................................................................................................1-6
Gas cylinders can explode if damaged..........................................................................................................1-6
Noise can damage hearing ...............................................................................................................................1-7
Pacemaker and hearing aid operation............................................................................................................1-7
A plasma arc can damage frozen pipes.........................................................................................................1-7
Additional safety information.............................................................................................................................1-7
Warning labels .....................................................................................................................................................1-9
Dry dust collection information......................................................................................................................1-11
Hypertherm
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SAFETY
RECOGNIZE SAFETY INFORMATION
The symbols shown in this section are used to
identify potential hazards. When you see a
safety symbol in this manual or on your machine,
understand the potential for personal injury, and follow
the related instructions to avoid the hazard.
FOLLOW SAFETY
INSTRUCTIONS
Read carefully all safety messages in this
manual and safety labels on your machine.
• Keep the safety labels on your machine in good
condition. Replace missing or damaged labels
immediately.
• Learn how to operate the machine and how to use
the controls properly. Do not let anyone operate it
without instruction.
• Keep your machine in proper working condition.
Unauthorized modifications to the machine may
affect safety and machine service life.
DANGER
WARNING CAUTION
Hypertherm uses American National Standards
Institute guidelines for safety signal words and
symbols. A signal word DANGER or WARNING is
used with a safety symbol. DANGER identifies the
most serious hazards.
• DANGER and WARNING safety labels are
located on your machine near specific hazards.
• DANGER safety messages precede related
instructions in the manual that will result in serious
injury or death if not followed correctly.
• WARNING safety messages precede related
instructions in this manual that may result in injury
or death if not followed correctly.
• CAUTION safety messages precede related
instructions in this manual that may result in
minor injury or damage to equipment if not
followed correctly.
CUTTING CAN CAUSE FIRE OR EXPLOSION
Fire Prevention
• Be sure the area is safe before doing any cutting.
Keep a fire extinguisher nearby.
• Remove all flammables within 35 feet (10 m) of
the cutting area.
• Quench hot metal or allow it to cool before
handling or before letting it touch combustible
materials.
• Never cut containers with potentially flammable
materials inside – they must be emptied and
properly cleaned first.
• Ventilate potentially flammable atmospheres
before cutting.
• When cutting with oxygen as the plasma gas,
an exhaust ventilation system is required.
Explosion Prevention
• Do not use the plasma system if explosive dust
or vapors may be present.
• Do not cut pressurized cylinders, pipes, or any
closed container.
• Do not cut containers that have held combustible
materials.
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WARNING
Explosion Hazard
Argon-Hydrogen and Methane
Hydrogen and methane are flammable gases that
present an explosion hazard. Keep flames away from
cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch
when using methane or argon-hydrogen plasma.
WARNING
Hydrogen Detonation with
Aluminum Cutting
• When cutting aluminum underwater, or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the workpiece
and detonate during plasma cutting operations.
• Install an aeration manifold on the floor of the water
table to eliminate the possibility of hydrogen
detonation. Refer to the Appendix section of this
manual for aeration manifold details.
Hypertherm
SAFETY
ELECTRIC SHOCK CAN KILL
Touching live electrical parts can cause a fatal shock
or severe burn.
• Operating the plasma system completes an
electrical circuit between the torch and the
workpiece. The workpiece and anything touching
the workpiece are part of the electrical circuit.
• Never touch the torch body, workpiece or the
water in a water table when the plasma system
is operating.
Electric Shock Prevention
All Hypertherm plasma systems use high
voltage in the cutting process (200 to 400 VDC
are common). Take the following precautions
when operating this system:
• Wear insulated gloves and boots, and keep your
body and clothing dry.
• Do not stand, sit or lie on – or touch – any wet
surface when using the plasma system.
• Insulate yourself from work and ground using dry
insulating mats or covers big enough to prevent
any physical contact with the work or ground.
If you must work in or near a damp area, use
extreme caution.
• Provide a disconnect switch close to the power
supply with properly sized fuses. This switch allows
the operator to turn off the power supply quickly in
an emergency situation.
• When using a water table, be sure that it is
correctly connected to earth ground.
• Install and ground this equipment according to the
instruction manual and in accordance with national
and local codes.
• Inspect the input power cord frequently for damage
or cracking of the cover. Replace a damaged
power cord immediately. Bare wiring can kill.
• Inspect and replace any worn or damaged torch
leads.
• Do not pick up the workpiece, including the waste
cutoff, while you cut. Leave the workpiece in place
or on the workbench with the work cable attached
during the cutting process.
• Before checking, cleaning or changing torch parts,
disconnect the main power or unplug the power
supply.
• Never bypass or shortcut the safety interlocks.
• Before removing any power supply or system
enclosure cover, disconnect electrical input power.
Wait 5 minutes after disconnecting the main power
to allow capacitors to discharge.
• Never operate the plasma system unless the power
supply covers are in place. Exposed power supply
connections present a severe electrical hazard.
• When making input connections, attach proper
grounding conductor first.
• Each Hypertherm plasma system is designed to be
used only with specific Hypertherm torches. Do not
substitute other torches which could overheat and
present a safety hazard.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
Use proper precautions when handling printed
circuit boards.
Hypertherm
• Store PC boards in anti-static containers.
• Wear a grounded wrist strap when handling
PC boards.
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SAFETY
TOXIC FUMES CAN CAUSE INJURY OR DEATH
The plasma arc by itself is the heat source used for
cutting. Accordingly, although the plasma arc has
not been identified as a source of toxic fumes, the
material being cut can be a source of toxic fumes
or gases that deplete oxygen.
Fumes produced vary depending on the metal that
is cut. Metals that may release toxic fumes include,
but are not limited to, stainless steel, carbon steel,
zinc (galvanized), and copper.
In some cases, the metal may be coated with a
substance that could release toxic fumes. Toxic
coatings include, but are not limited to, lead (in
some paints), cadmium (in some paints and fillers),
and beryllium.
Gases produced by plasma cutting vary based on
the material to be cut and the method of cutting,
but may include ozone, oxides of nitrogen,
hexavalent chromium, hydrogen, and other
substances if such are contained in or released
by the material being cut.
Caution should be taken to minimize exposure
to fumes produced by any industrial process.
Depending upon the chemical composition and
concentration of the fumes (as well as other factors,
such as ventilation), there may be a risk of physical
illness, such as birth defects or cancer.
• Duration of cutting or gouging.
• Size, air volume, ventilation and filtration of the
work area.
• Personal protective equipment.
• Number of welding and cutting systems
in operation.
• Other site processes that may produce fumes.
If the workplace must conform to national or local
regulations, only monitoring or testing done at the
site can determine whether the site is above or
below allowable levels.
To reduce the risk of exposure to fumes:
• Remove all coatings and solvents from the metal
before cutting.
• Use local exhaust ventilation to remove fumes
from the air.
• Do not inhale fumes. Wear an air-supplied
respirator when cutting any metal coated with,
containing, or suspected to contain toxic
elements.
• Assure that those using welding or cutting
equipment, as well as air-supplied respiration
devices, are qualified and trained in the proper
use of such equipment.
It is the responsibility of the equipment and site
owner to test the air quality in the area where the
equipment is used and to ensure that the air quality
in the workplace meets all local and national
standards and regulations.
• Never cut containers with potentially toxic
materials inside. Empty and properly clean the
container first.
The air quality level in any relevant workplace
depends on site-specific variables such as:
• Table design (wet, dry, underwater).
• Material composition, surface finish, and
composition of coatings.
• Volume of material removed.
• Consult with a local expert to implement a site
plan to ensure safe air quality.
1-4
11/08
• Monitor or test the air quality at the site as
needed.
Hypertherm
SAFETY
A PLASMA ARC CAN CAUSE INJURY AND BURNS
Instant-On Torches
Plasma arc comes on immediately when the torch
switch is activated.
The plasma arc will cut quickly through gloves
and skin.
• Keep away from the torch tip.
• Do not hold metal near the cutting path.
• Never point the torch toward yourself or others.
ARC RAYS CAN BURN EYES AND SKIN
Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can
burn eyes and skin.
• Use eye protection in accordance with applicable national or local codes.
• Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate
lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.
Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks and
hot metal.
• Gauntlet gloves, safety shoes and hat.
• Flame-retardant clothing to cover all exposed areas.
• Cuffless trousers to prevent entry of sparks and slag.
• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.
Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:
• Paint walls and other surfaces with dark colors to reduce reflection.
• Use protective screens or barriers to protect others from flash and glare.
• Warn others not to watch the arc. Use placards or signs.
Arc current
(amps)
Less than 40 A
41 to 60 A
61 to 80 A
81 to 125 A
126 to 150 A
151 to 175 A
176 to 250 A
251 to 300 A
301 to 400 A
401 to 800 A
Hypertherm
Minimum protective
shade number
(ANSI Z49.1:2005)
5
6
8
8
8
8
8
8
9
10
Suggested shade
number for comfort
(ANSI Z49.1:2005)
5
6
8
9
9
9
9
9
12
14
OSHA 29CFR
1910.133(a)(5)
Europe
EN168:2002
8
8
8
8
8
8
8
8
9
10
9
9
9
9
10
11
12
13
13
1-5
11/08
SAFETY
GROUNDING SAFETY
Work Cable Attach the work cable securely to the
workpiece or the work table with good metal-to-metal
contact. Do not connect it to the piece that will fall
away when the cut is complete.
Work Table Connect the work table to an earth
ground, in accordance with appropriate national or
local electrical codes.
Input Power
• Be sure to connect the power cord ground wire
to the ground in the disconnect box.
• If installation of the plasma system involves
connecting the power cord to the power supply,
be sure to connect the power cord ground wire
properly.
• Place the power cord's ground wire on the stud
first, then place any other ground wires on top
of the power cord ground. Fasten the retaining
nut tightly.
• Tighten all electrical connections to avoid
excessive heating.
COMPRESSED GAS EQUIPMENT
SAFETY
• Never lubricate cylinder valves or regulators with
oil or grease.
• Use only correct gas cylinders, regulators, hoses
and fittings designed for the specific application.
GAS CYLINDERS CAN
EXPLODE IF DAMAGED
Gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode.
• Maintain all compressed gas equipment and
associated parts in good condition.
• Handle and use compressed gas cylinders in
accordance with applicable national or local
codes.
• Label and color-code all gas hoses to identify
the type of gas in each hose. Consult applicable
national or local codes.
• Never use a cylinder that is not upright and
secured in place.
• Keep the protective cap in place over valve
except when the cylinder is in use or connected
for use.
• Never allow electrical contact between the
plasma arc and a cylinder.
• Never expose cylinders to excessive heat, sparks,
slag or open flame.
• Never use a hammer, wrench or other tool to
open a stuck cylinder valve.
1-6
11/08
Hypertherm
SAFETY
NOISE CAN DAMAGE
HEARING
Prolonged exposure to noise from cutting or
gouging can damage hearing.
• Use approved ear protection when using
plasma system.
• Warn others nearby about the noise hazard.
PACEMAKER AND
HEARING AID OPERATION
Pacemaker and hearing aid operation can be
affected by magnetic fields from high currents.
Pacemaker and hearing aid wearers should
consult a doctor before going near any plasma arc
cutting and gouging operations.
To reduce magnetic field hazards:
• Keep both the work cable and the torch lead
to one side, away from your body.
A PLASMA ARC
CAN DAMAGE
FROZEN PIPES
• Route the torch leads as close as possible to
the work cable.
• Do not wrap or drape the torch lead or work
cable around your body.
Frozen pipes may be damaged or can burst if you
attempt to thaw them with a plasma torch.
• Keep as far away from the power supply
as possible.
ADDITIONAL SAFETY INFORMATION
7. CSA Standard W117.2, Code for Safety in Welding
and Cutting, Canadian Standards Association
Standard Sales, 178 Rexdale Boulevard, Rexdale,
Ontario M9W 1R3, Canada
1. ANSI Standard Z49.1, Safety in Welding and Cutting,
American Welding Society, 550 LeJeune Road, P.O. Box
351020, Miami, FL 33135
2. ANSI Standard Z49.2, Fire Prevention in the Use of
Cutting and Welding Processes, American National
Standards Institute, 1430 Broadway, New York, NY
10018
3. ANSI Standard Z87.1, Safe Practices for Occupation
and Educational Eye and Face Protection, American
National Standards Institute, 1430 Broadway, New York,
NY 10018
4. AWS F4.1, Recommended Safe Practices for the
Preparation for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
American Welding Society, 550 LeJeune Road, P.O. Box
351040, Miami, FL 33135
8. NFPA Standard 51B, Cutting and Welding
Processes, National Fire Protection Association,
470 Atlantic Avenue, Boston, MA 02210
9. NFPA Standard 70–1978, National Electrical Code,
National Fire Protection Association, 470 Atlantic
Avenue, Boston, MA 02210
10. OSHA, Safety and Health Standards, 29FR 1910
U.S. Government Printing Office, Washington, D.C.
20402
11. AWS Safety and Health Fact Sheets, American
Welding Society 550 LeJeune Road, P.O. Box
351040, Miami, FL 33135
www.aws.org/technical/facts/
5. AWS F5.2, Recommended Safe Practices for Plasma
Arc Cutting, American Welding Society, 550 LeJeune
Road, P.O. Box 351040, Miami, FL 33135
6. CGA Pamphlet P-1, Safe Handling of Compressed
Gases in Cylinders, Compressed Gas Association,
1235 Jefferson Davis Highway, Arlington, VA 22202
Hypertherm
1-7
11/08
SAFETY
SYMBOLS AND MARKINGS
Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to
differences and conflicts in national regulations, not all marks are applied to every version of a product.
S mark symbol
The S mark symbol indicates that the power supply and torch are suitable for operations carried out
in environments with increased hazard of electrical shock per IEC 60974-1.
CSA mark
Hypertherm products with a CSA mark meet the United States and Canadian regulations for
product safety. The products were evaluated, tested, and certified by CSA-International. Alternatively
the product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL)
accredited in both the United States and Canada, such as Underwriters Laboratories, Incorporated
(UL) or TÜV.
CE marking
The CE marking signifies the manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of Hypertherm products with a CE marking located on
or near the data plate have been tested for compliance with the European Low Voltage Directive and
the European Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the
European EMC Directive are incorporated within versions of the product with a CE marking.
GOST-R mark
CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product
safety and EMC requirements for export to the Russian Federation.
c-Tick mark
CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required
for sale in Australia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and
found compliant with product safety regulations required for sale in China.
1-8
11/08
Hypertherm
SAFETY
WARNING LABEL
This warning label is affixed to some power supplies. It is important that the operator
and maintenance technician understand the intent of these warning symbols as
described. The numbered text corresponds to the numbered boxes on the label.
Read and follow these instructions, employer safety
practices, and material safety data sheets. Refer to
ANS Z49.1, “Safety in Welding, Cutting and Allied
Processes” from American Welding Society
(http://www.aws.org) and OSHA Safety and Health
Standards, 29 CFR 1910 (http://www.osha.gov).
WARNING
Plasma cutting can be injurious to operator and persons
in the work area. Consult manual before operating. Failure
to follow all these safety instructions can result in death.
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi.
Il s’allume instantanément quand on l’amorce;
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Hazardous voltage. Risk of electric shock or burn.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou
endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Plasma fumes can be hazardous.
4. Les fumées plasma peuvent être dangereuses.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
4.1 Ne pas inhaler les fumées
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Arc rays can burn eyes and injure skin.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
equipment. Use torches specified in the manual. Keep non-qualified
personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn (PN 110584 Rev C).
2.1
2.2
2.3
3.
3.1
3.2
3.3
Cutting sparks can cause explosion or fire.
Do not cut near flammables.
Have a fire extinguisher nearby and ready to use.
Do not use a drum or other closed container as
a cutting table.
Plasma arc can injure and burn; point the nozzle
away from yourself. Arc starts instantly when
triggered.
Turn off power before disassembling torch.
Do not grip the workpiece near the cutting path.
Wear complete body protection.
Hazardous voltage. Risk of electric shock or
burn.
Wear insulating gloves. Replace gloves when
wet or damaged.
Protect from shock by insulating yourself from
work and ground.
Disconnect power before servicing. Do not
touch live parts.
Hypertherm
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2.1 Turn off power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
6. Become trained. Only qualified personnel should operate this
2.
1. Les étincelles de coupage peuvent provoquer une explosion
ou un incendie.
2. Plasma arc can injure and burn; point the nozzle away
from yourself. Arc starts instantly when triggered.
5.1 Wear correct and appropriate protective equipment to protect
head, eyes, ears, hands, and body. Button shirt collar. Protect ears
from noise. Use welding helmet with the correct shade of filter.
1.
1.1
1.2
1.3
AVERTISSEMENT
Le coupage plasma peut être préjudiciable pour l’opérateur et les personnes qui se
trouvent sur les lieux de travail. Consulter le manuel avant de faire fonctionner. Le
non respect des ces instructions de sécurité peut entraîner la mort.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles
contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation. Seul le personnel qualifié a le droit de faire
fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le
manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée (PN 110584 Rev C).
4.2 Use forced ventilation or local exhaust to remove
the fumes.
4.3 Do not operate in closed spaces. Remove fumes
with ventilation.
5.1 Wear correct and appropriate protective
equipment to protect head, eyes, ears, hands,
and body. Button shirt collar. Protect ears from
noise. Use welding helmet with the correct
shade of filter.
6. Become trained. Only qualified personnel should
operate this equipment. Use torches specified in
the manual. Keep non-qualified personnel and
children away.
Replace if it is missing, damaged, or worn.
1-9
11/08
SAFETY
WARNING LABEL
1.
This warning label is affixed to some power supplies. It is
important that the operator and maintenance technician
understand the intent of these warning symbols as described.
The numbered text corresponds to the numbered boxes on
the label.
1.1
1.2
1.3
2.
2.1
2.2
2.3
3.
3.1
3.2
3.3
4.
www.hypertherm.com/weee
1-10
11/08
110647 Rev. A
Cutting sparks can cause explosion
or fire.
Do not cut near flammables.
Have a fire extinguisher nearby and
ready to use.
Do not use a drum or other closed
container as a cutting table.
Plasma arc can injure and burn;
point the nozzle away from yourself.
Arc starts instantly when triggered.
Turn off power before disassembling
torch.
Do not grip the workpiece near the
cutting path.
Wear complete body protection.
Hazardous voltage. Risk of electric
shock or burn.
Wear insulating gloves. Replace
gloves when wet or damaged.
Protect from shock by insulating
yourself from work and ground.
Disconnect power before servicing.
Do not touch live parts.
Plasma fumes can be hazardous.
4.2 Use forced ventilation or local
exhaust to remove the fumes.
4.3 Do not operate in closed spaces.
Remove fumes with ventilation.
5. Arc rays can burn eyes and injure
skin.
5.1 Wear correct and appropriate
protective equipment to protect
head, eyes, ears, hands, and body.
Button shirt collar. Protect ears from
noise. Use welding helmet with the
correct shade of filter.
6. Become trained. Only qualified
personnel should operate this
equipment. Use torches specified in
the manual. Keep non-qualified
7. Do not remove, destroy, or cover
this label. Replace if it is missing,
damaged, or worn.
Hypertherm
SAFETY
DRY DUST COLLECTION INFORMATION
At some sites, dry dust can represent a potential explosion hazard.
The U.S. National Fire Protection Association’s 2007 edition of NFPA standard 68, “Explosion Protection by
Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of
devices and systems to vent combustion gases and pressures after any deflagration event. Consult with the
manufacturer or installer of any dry dust collection system for applicable requirements before you install a new
dry dust collection system or make significant changes in the process or materials used with an existing dry
dust collection system.
Consult your local “Authority Having Jurisdiction” (AHJ) to determine whether any edition of NFPA 68 has
been “adopted by reference” in your local building codes.
Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration, AHJ, adopted by
reference, the Kst value, deflagration index, and other terms.
Note 1 – Hypertherm’s interpretation of these new requirements is that unless a site-specific evaluation has
been completed to determine that all dust generated is not combustible, the 2007 edition of NFPA 68
requires the use of explosion vents designed to the worst-case Kst value (see annex F) that could be
generated from dust so that the explosion vent size and type can be designed. NFPA 68 does not specifically
identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems, but it
does apply these new requirements to all dry dust collection systems.
Note 2 – Users of Hypertherm manuals should consult and comply with all applicable federal, state, and local
laws and regulations. Hypertherm does not, by the publication of any Hypertherm manual, intend to urge
action that is not in compliance with all applicable regulations and standards, and this manual may never be
construed as doing so.
Hypertherm
1-11
11/08
SAFETY
1-12
11/08
Hypertherm
Section 1a
SÉCURITÉ
Dans cette section :
Identifier les consignes de sécurité ..............................................................................................................1a-2
Suivre les instructions de sécurité ................................................................................................................1a-2
Le coupage peut provoquer un incendie ou une explosion ....................................................................1a-2
Les chocs électriques peuvent être fatals ..................................................................................................1a-3
L’électricité statique peut endommager les cartes de circuits imprimés .............................................1a-3
Les vapeurs toxiques peuvent provoquer des blessures ou la mort .....................................................1a-4
L’arc plasma peut provoquer des blessures ou des brûlures .................................................................1a-5
Les rayons de l’arc peuvent brûler les yeux et la peau.............................................................................1a-5
Mise à la masse et à la terre...........................................................................................................................1a-6
Sécurité des bouteilles de gaz comprimé...................................................................................................1a-6
Les bouteilles de gaz comprimé peuvent exploser en cas de dommages ..........................................1a-6
Le bruit peut provoquer des problèmes auditifs ........................................................................................1a-7
Pacemakers et prothèses auditives ..............................................................................................................1a-7
Un arc plasma peut endommager les tuyaux gelés...................................................................................1a-7
Symboles et marquage....................................................................................................................................1a-8
Étiquettes de sécurité......................................................................................................................................1a-9
Information sur le dépoussiérage ...............................................................................................................1a-11
Hypertherm
1a-1
11/08
SÉCURITÉ
IDENTIFIER LES CONSIGNES
DE SÉCURITÉ
DANGER
AVERTISSEMENT
ATTENTION
Hypertherm adopte les lignes directrices de l’American
National Standards Institute relativement aux termes, aux
symboles et à la signalisation de sécurité. Les signaux
DANGER ou AVERTISSEMENT sont utilisés avec un symbole
de sécurité, DANGER correspondant aux risques les plus
sérieux.
• Les étiquettes de sécurité DANGER et AVERTISSEMENT
sont situées sur la machine pour signaler certains dangers
SUIVRE LES INSTRUCTIONS
spécifiques.
DE SÉCURITÉ
Lire attentivement toutes les consignes de sécurité • Les messages de sécurité DANGER précèdent les
directives associées dans le manuel qui, si elles ne sont pas
dans le présent manuel et sur les étiquettes de sécurité se
suivies scrupuleusement, entraînent des blessures graves
trouvant sur la machine.
voire mortelles.
• Les étiquettes de sécurité doivent rester lisibles. Remplacer
• Les messages d’AVERTISSEMENT précèdent les
immédiatement les étiquettes manquantes ou abîmées.
instructions d’utilisation expliquées dans ce manuel et
• Apprendre à faire fonctionner la machine et à utiliser
signalent les risques de blessures ou de mort au cas où ces
correctement les commandes. Ne laisser personne utiliser
instructions ne seraient pas suivies correctement.
la machine sans connaître son fonctionnement.
• Les messages de sécurité ATTENTION précèdent les
• Garder la machine en bon état. Des modifications non
directives associées dans le manuel qui, si elles ne sont pas
autorisées sur la machine peuvent engendrer des problèmes
suivies scrupuleusement, peuvent entraîner des blessures
de sécurité et raccourcir la durée d’utilisation de l’équipement.
secondaires ou endommager l’équipement.
Les symboles indiqués dans cette section sont utilisés
pour identifier les risques éventuels. Si vous trouvez un symbole
de sécurité, que ce soit dans ce manuel ou sur l’équipement,
soyez conscient des risques de blessures et suivez les
instructions correspondantes afin d’éviter ces risques.
LE COUPAGE PEUT PROVOQUER
UN INCENDIE OU UNE EXPLOSION
Prévention des incendies
• Avant de commencer, s’assurer que la zone de coupage
ne présente aucun danger. Conserver un extincteur
à proximité.
• Éloigner toute matière inflammable à une distance
d’au moins 10 m du poste de coupage.
• Tremper le métal chaud ou le laisser refroidir avant
de le manipuler ou avant de le mettre en contact avec
des matériaux combustibles.
• Ne jamais couper des récipients pouvant contenir
des matières inflammables avant de les avoir vidés
et nettoyés correctement.
• Aérer toute atmosphère potentiellement inflammable
avant d’utiliser un système plasma.
• Lors de l’utilisation d’oxygène comme gaz plasma, un
système de ventilation par aspiration est nécessaire.
Prévention des explosions
• Ne pas couper en présence de poussière ou de vapeurs.
• Ne pas couper de bouteilles, de tuyaux ou autres
récipients fermés et pressurisés.
• Ne pas couper de récipients contenant des matières
combustibles.
1a-2
11/08
AVERTISSEMENT
Risque d’explosion
argon-hydrogène et méthane
L’hydrogène et le méthane sont des gaz inflammables
et potentiellement explosifs. Conserver à l’écart de toute
flamme les bouteilles et tuyaux contenant des mélanges
à base d’hydrogène ou de méthane. Maintenir toute
flamme et étincelle à l’écart de la torche lors de l’utilisation
d’un plasma d’argon-hydrogène ou de méthane.
AVERTISSEMENT
Détonation de l’hydrogène lors du
coupage de l’aluminium
• Lors du coupage de l’aluminium sous l’eau, ou si l’eau
touche la partie inférieure de la pièce d’aluminium, de
l’hydrogène libre peut s’accumuler sous la pièce à couper
et détonner lors du coupage plasma.
• Installer un collecteur d’aération au fond de la table à eau
afin d’éliminer les risques de détonation de l’hydrogène.
Se référer à l’annexe du manuel pour plus de
renseignements sur les collecteurs d’aération.
Hypertherm
SÉCURITÉ
LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS
Toucher une pièce électrique sous tension peut provoquer
un choc électrique fatal ou des brûlures graves.
• La mise en fonctionnement du système plasma ferme
un circuit électrique entre la torche et la pièce à couper.
La pièce à couper et tout autre élément en contact avec
cette pièce font partie du circuit électrique.
• Ne jamais toucher le corps de la torche, la pièce à couper
ou l’eau de la table à eau pendant le fonctionnement du
système plasma.
Prévention des chocs électriques
Tous les systèmes plasma Hypertherm utilisent des hautes
tensions pour le coupage (souvent de 200 à 400 V). On
doit prendre les précautions suivantes quand on utilise le
système plasma :
• Porter des bottes et des gants isolants et garder le corps
et les vêtements au sec.
• Ne pas se tenir, s’asseoir ou se coucher sur une surface
mouillée, ni la toucher quand on utilise le système plasma.
• S’isoler de la surface de travail et du sol en utilisant des
tapis isolants secs ou des couvertures assez grandes
pour éviter tout contact physique avec le travail ou le sol.
S’il s’avère nécessaire de travailler dans ou près d’un
endroit humide, procéder avec une extrême prudence.
• Installer un sectionneur avec fusibles appropriés, à
proximité de la source de courant. Ce dispositif permet à
l’opérateur d’arrêter rapidement la source de courant en
cas d’urgence.
• En cas d’utilisation d’une table à eau, s’assurer que cette
dernière est correctement mise à la terre.
• Installer et mettre à la terre l’équipement selon les
instructions du présent manuel et conformément aux
codes électriques locaux et nationaux.
• Inspecter fréquemment le cordon d’alimentation primaire
pour s’assurer qu’il n’est ni endommagé, ni fendu.
Remplacer immédiatement un cordon endommagé.
Un câble dénudé peut tuer.
• Inspecter et remplacer les câbles de la torche qui sont
usés ou endommagés.
• Ne pas saisir la pièce à couper ni les chutes lors du
coupage. Laisser la pièce à couper en place ou sur la
table de travail, le câble de retour connecté lors du
coupage.
• Avant de vérifier, de nettoyer ou de remplacer les pièces
de la torche, couper l’alimentation ou débrancher la prise
de courant.
• Ne jamais contourner ou court-circuiter les verrouillages
de sécurité.
• Avant d’enlever le capot du système ou de la source de
courant, couper l’alimentation électrique. Attendre ensuite
5 minutes pour que les condensateurs se déchargent.
• Ne jamais faire fonctionner le système plasma sans que
les capots de la source de courant ne soient en place.
Les raccords exposés de la source de courant sont
extrêmement dangereux.
• Lors de l’installation des connexions, attacher tout
d’abord la prise de terre appropriée.
• Chaque système plasma Hypertherm est conçu pour
être utilisé uniquement avec des torches Hypertherm
spécifiques. Ne pas utiliser des torches inappropriées
qui pourraient surchauffer et présenter des risques pour
la sécurité.
L’ÉLECTRICITÉ STATIQUE PEUT ENDOMMAGER
LES CARTES DE CIRCUITS IMPRIMÉS
On doit prendre les précautions qui s’imposent quand on
manipule les circuits imprimés.
Hypertherm
• On doit ranger les cartes de circuits imprimés dans des
contenants antistatiques.
• On doit porter un bracelet antistatique quand on
manipule les cartes de circuits imprimés.
1a-3
11/08
SÉCURITÉ
LES VAPEURS TOXIQUES PEUVENT PROVOQUER
DES BLESSURES OU LA MORT
L’arc plasma est lui-même la source de chaleur utilisée
pour le coupage. Par conséquent, bien que l’arc plasma
n’ait pas été reconnu comme une source de vapeurs
toxiques, le matériau coupé peut être une source de
vapeurs ou de gaz toxiques qui épuisent l’oxygène.
Les vapeurs produites varient selon le métal coupé.
Les métaux qui peuvent dégager des vapeurs toxiques
comprennent, entre autres, l’acier inoxydable, l’acier au
carbone, le zinc (galvanisé) et le cuivre.
Dans certains cas, le métal peut être revêtu d’une
substance susceptible de dégager des vapeurs toxiques.
Les revêtements toxiques comprennent entre autres,
le plomb (dans certaines peintures), le cadmium (dans
certaines peintures et enduits) et le béryllium.
Les gaz produits par le coupage plasma varient selon
le matériau à couper et la méthode de coupage, mais
ils peuvent comprendre l’ozone, les oxydes d’azote,
le chrome hexavalent, l’hydrogène et autres substances
présentes dans le matériau coupé ou en émanent.
On doit prendre les précautions qui s’imposent pour
réduire au minimum l’exposition aux vapeurs produites par
tout processus industriel. Selon la composition chimique
et la concentration des vapeurs (ainsi que d’autres
facteurs comme la ventilation), il peut y avoir un risque de
maladie physique, comme des malformations ou le cancer.
Il incombe au propriétaire du matériel et du site de vérifier
la qualité de l’air dans le secteur où l’on utilise le matériel
et de s’assurer que la qualité de l’air sur les lieux de travail
répond aux normes et réglementation locales et nationales.
1a-4
11/08
Le niveau de qualité de l’air dans tout lieu de travail
dépend des variables propres au site comme :
• Type de table (humide, sèche, sous l’eau).
• Composition du matériau, fini de la surface
et composition des revêtements.
• Volume de matériau enlevé.
• Durée du coupage ou du gougeage.
• Dimensions, volume d’air, ventilation et filtration
de la zone de travail.
• Équipement de protection individuelle.
• Nombre de systèmes de soudage et de coupage
en fonctionnement.
• Autres procédés du site qui peuvent produire
des vapeurs.
Si les lieux de travail doivent être conformes aux
règlements nationaux ou locaux, seuls les contrôles ou les
essais effectués au site peuvent déterminer si celui-ci se
situe au-dessus ou au-dessous des niveaux admissibles.
Pour réduire le risque d’exposition aux vapeurs :
• Éliminer tout revêtement et solvant du métal avant
le coupage.
• Utiliser la ventilation d’extraction locale pour éliminer
les vapeurs de l’air.
• Ne pas inhaler les vapeurs. Porter un respirateur
à adduction d’air quand on coupe des métaux revêtus
d’éléments toxiques ou qui en contiennent ou sont
susceptibles d’en contenir.
• S’assurer que les personnes qui utilisent un matériel
de soudage ou de coupage ainsi que les dispositifs de
respiration par adduction d’air sont qualifiés et ont reçu
la formation sur la bonne utilisation d’un tel matériel.
• Ne jamais couper les contenants dans lesquels il peut
y avoir des matériaux toxiques. En premier lieu, vider et
nettoyer correctement le contenant.
• Contrôler ou éprouver la qualité de l’air au site selon
les besoins.
• Consulter un expert local pour mettre en œuvre un plan
du site afin d’assurer une qualité de l’air sûre.
Hypertherm
SÉCURITÉ
L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES
Torches à allumage instantané
L’arc plasma s’allume immédiatement après que la torche
soit mise en marche.
L’arc plasma coupe facilement les gants et la peau.
• Rester éloigné de l’extrémité de la torche.
• Ne pas tenir de métal près de la trajectoire de coupe.
• Ne jamais pointer la torche vers soi ou d’autres
personnes.
LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU
Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et
infrarouges) qui peuvent brûler les yeux et la peau.
• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.
• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux et encore masque de soudure) avec des
verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.
Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les
rayons ultraviolets, les étincelles et le métal brûlant :
• Gants à crispin, chaussures et casque de sécurité.
• Vêtements ignifuges couvrant toutes les parties exposées du corps.
• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.
• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.
Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière
ultraviolette :
• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.
• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de
la réverbération.
• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.
Courant de l’arc
(A)
Moins de 40 A
41 à 60 A
61 à 80 A
81 à 125 A
126 à 150 A
151 à 175 A
176 à 250 A
251 à 300 A
301 à 400 A
401 à 800 A
Hypertherm
Indice de protection Indice de protection
suggéré pour assurer OSHA 29CFR
minimum
le confort
1910.133(a)(5)
(ANSI Z49.1:2005)
(ANSI Z49.1:2005)
5
5
8
6
6
8
8
8
8
8
9
8
8
9
8
8
9
8
8
9
8
8
9
8
9
12
9
10
14
10
Europe
EN168:2002
9
9
9
9
10
11
12
13
13
1a-5
11/08
SÉCURITÉ
MISE À LA MASSE ET À LA TERRE
Câble de retour Bien fixer le câble de retour (ou de
masse) à la pièce à couper ou à la table de travail de façon
à assurer un bon contact métal-métal. Ne pas fixer le câble
de retour à la partie de la pièce qui doit se détacher.
Table de travail Raccorder la table de travail à la terre,
conformément aux codes de sécurité locaux ou nationaux
appropriés.
Alimentation
• S’assurer que le fil de terre du cordon d’alimentation est
connecté à la terre dans le coffret du sectionneur.
• S’il est nécessaire de brancher le cordon d’alimentation
à la source de courant lors de l’installation du système,
s’assurer que le fil de terre est correctement branché.
• Placer tout d’abord le fil de terre du cordon
d’alimentation sur le plot de mise à la terre puis placer
les autres fils de terre par-dessus. Bien serrer l’écrou
de retenue.
• S’assurer que toutes les connexions sont bien serrées
pour éviter la surchauffe.
SÉCURITÉ DES BOUTEILLES
DE GAZ COMPRIMÉ
• Ne jamais lubrifier les robinets des bouteilles ou les
régulateurs avec de l’huile ou de la graisse.
LES BOUTEILLES DE
GAZ COMPRIMÉ
PEUVENT EXPLOSER
EN CAS DE DOMMAGES
• Utiliser uniquement les bouteilles, régulateurs, tuyaux
et accessoires appropriés et conçus pour chaque
application spécifique.
Les bouteilles de gaz contiennent du gaz à haute
pression. Si une bouteille est endommagée, elle peut
exploser.
• Entretenir l’équipement et les pièces d’équipement
à gaz comprimé afin de les garder en bon état.
• Manipuler et utiliser les bouteilles de gaz comprimé
conformément aux codes locaux ou nationaux.
• Étiqueter et coder avec des couleurs tous les tuyaux
de gaz afin d’identifier le type de gaz contenu dans
chaque tuyau. Se référer aux codes locaux ou nationaux
en vigueur.
• Ne jamais utiliser une bouteille qui n’est pas placée
à la verticale et bien assujettie.
• Le capuchon de protection doit être placé sur le robinet
sauf si la bouteille est en cours d’utilisation ou
connectée pour utilisation.
• Éviter à tout prix le contact électrique entre l’arc plasma
et une bouteille.
• Ne jamais exposer des bouteilles à une chaleur
excessive, aux étincelles, aux scories ou aux flammes
nues.
• Ne jamais utiliser des marteaux, des clés ou d’autres
outils pour débloquer le robinet des bouteilles.
1a-6
11/08
Hypertherm
SÉCURITÉ
LE BRUIT PEUT PROVOQUER
DES PROBLÈMES AUDITIFS
Une exposition prolongée au bruit du coupage ou du
gougeage peut provoquer des problèmes auditifs.
• Utiliser un casque de protection homologué lors de
l’utilisation du système plasma.
• Prévenir les personnes aux alentours des risques
encourus en cas d’exposition au bruit.
UN ARC PLASMA PEUT
ENDOMMAGER LES
TUYAUX GELÉS
Les tuyaux gelés peuvent être endommagés ou éclater
si l'on essaie de les dégeler avec une torche plasma.
Hypertherm
PACEMAKERS ET
PROTHÈSES AUDITIVES
Les champs magnétiques produits par les courants
à haute tension peuvent affecter le fonctionnement
des prothèses auditives et des pacemakers.
Les personnes portant ce type d’appareil doivent
consulter un médecin avant de s’approcher d’un lieu
où s’effectue le coupage ou le gougeage plasma.
Pour réduire les risques associés aux champs
magnétiques :
• Garder loin de soi et du même côté du corps le câble
de retour et le faisceau de la torche.
• Faire passer le faisceau de la torche le plus près
possible du câble de retour.
• Ne pas s’enrouler le faisceau de la torche ou le câble
de retour autour du corps.
• Se tenir le plus loin possible de la source de courant.
1a-7
11/08
SÉCURITÉ
SYMBOLES ET MARQUAGE
Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique ou à
proximité. En raison des différends et des conflits relatifs aux règlements nationaux, toutes les marques ne sont pas
appliquées à chaque version d’un produit.
Symbole marque S
Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux effectués
dans les milieux à risque accru de choc électrique selon l’IEC 60974-1.
Marque CSA
Les produits Hypertherm comportant la marque CSA répondent aux règlements des États-Unis et du Canada
relatifs à la sécurité du produit. Les produits sont évalués, mis à l’essai et certifiés par la CSA-International.
En outre, le produit peut porter une marque d’un des laboratoires d’essai reconnus sur le plan national (NRTL)
accrédité aux États-Unis et au Canada comme les Underwriters Laboratories, Incorporated (UL) ou TÜV.
Marque CE
La marque CE signifie la déclaration de conformité du fabricant aux directives et normes européennes
applicables. Seules les versions des produits Hypertherm portant la marque CE placée sur la plaque
signalétique ou à proximité ont été mises à l’essai de conformité à la directive européenne sur la basse
tension et la compatibilité électromagnétique européenne (CEM). Les filtres CEM qui doivent se conformer
à la directive CEM européenne sont intégrés aux versions du produit portant la marque CE.
Marque GOST-R
Les versions CE des produits Hypertherm qui portent la marque de conformité GOST-R répondent aux
exigences de sécurité du produit et de CEM en vue de l’exportation à la Fédération russe.
Marque c-Tick
Les versions CE des produits Hypertherm portant la marque c-Tick sont conformes aux règlements CEM
prescrits pour la vente en Australie et en Nouvelle-Zélande.
Marque CCC
La marque de certification obligatoire en Chine (CCC) indique que le produit a été mis à l’essai et déclaré
conforme aux règlements de sécurité du produit prescrits pour la vente en Chine.
1a-8
11/08
Hypertherm
SÉCURITÉ
ÉTIQUETTE DE SÉCURITÉ
Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et
le technicien de maintenance comprennent la signification des symboles de sécurité.
Les numéros de la liste correspondent aux numéros des images.
WARNING
endommagés.
1.3
2.
2.1
2.2
2.3
3.
3.1
3.2
3.3
Les étincelles de coupage peuvent provoquer une
explosion ou un incendie.
Ne pas couper près des matières inflammables.
Un extincteur doit se trouver sur les lieux et prêt
à être utilisé.
Ne pas utiliser un fût ou un autre contenant fermé
comme table de coupe.
L’arc plasma peut blesser et brûler ; ne jamais pointer
la buse vers soi. L’arc s’amorce instantanément quand
on appuie sur la gâchette.
Couper l’alimentation avant de démonter la torche.
Ne pas saisir la pièce près de la trajectoire de coupage.
Se protéger entièrement le corps.
Tension dangereuse. Risque de choc électrique
ou de brûlure.
Porter des gants isolants. Remplacer les gants s’ils
sont humides ou endommagés.
Se protéger contre les chocs en s’isolant de la pièce
et de la terre.
Couper l’alimentation avant d’entretenir. Ne pas
toucher les pièces sous tension.
Hypertherm
1.1
1.2
ou un incendie.
1.
AVERTISSEMENT
4. Les fumées du plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées.
4.2 Utiliser une ventilation forcée ou par aspiration
à la source pour éliminer les fumées.
4.3 Ne pas utiliser dans des espaces clos. Chasser
les fumées avec la ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser
la peau.
5.1 Porter un bon équipement de protection pour se
protéger la tête, les yeux, les oreilles, les mains et le
corps. Boutonner le col de la chemise. Se protéger les
oreilles contre le bruit. Utiliser le masque de soudage
avec le filtre ayant le bon indice de protection.
6. S’entraîner. Seul le personnel qualifié doit faire
fonctionner cet équipement. Utiliser les torches
prescrites dans le manuel. Tenir le personnel non
qualifié et les enfants à l’écart.
7. Ne pas enlever, détruire ou couvrir cette étiquette.
La remplacer si elle est manquante, endommagée
ou usée.
1a-9
11/08
SÉCURITÉ
1.
ÉTIQUETTE DE SÉCURITÉ
Cette étiquette est affichée sur la source de courant. Il est important que
l’utilisateur et le technicien de maintenance comprennent la signification
des symboles de sécurité. Les numéros de la liste correspondent aux
numéros des images.
1.1
1.2
1.3
2.
2.1
2.2
2.3
3.
3.1
3.2
3.3
4.
4.1
4.2
4.3
5.
5.1
110647 Rev. A
6.
7.
1a-10
11/08
Les étincelles de coupage peuvent
provoquer une explosion ou un incendie.
Ne pas couper près des matières
inflammables.
Un extincteur doit se trouver sur les lieux
et prêt à être utilisé.
Ne pas utiliser un fût ou un autre contenant
fermé comme table de coupe.
L’arc plasma peut blesser et brûler ;
ne jamais pointer la buse vers soi. L’arc
s’amorce instantanément quand on appuie
sur la gâchette.
Couper l’alimentation avant de démonter
la torche.
Ne pas saisir la pièce près de la trajectoire
de coupage.
Se protéger entièrement le corps.
Tension dangereuse. Risque de choc
électrique ou de brûlure.
Porter des gants isolants. Remplacer les
gants s’ils sont humides ou endommagés.
Se protéger contre les chocs en s’isolant
de la pièce et de la terre.
Couper l’alimentation avant d’entretenir.
Ne pas toucher les pièces sous tension.
Les fumées du plasma peuvent être
dangereuses.
Ne pas inhaler les fumées.
Utiliser une ventilation forcée ou par
aspiration à la source pour éliminer les
fumées.
Ne pas utiliser dans des espaces clos.
Chasser les fumées avec la ventilation.
Les rayons d’arc peuvent brûler les yeux
et blesser la peau.
Porter un bon équipement de protection
pour se protéger la tête, les yeux, les
oreilles, les mains et le corps. Boutonner le
col de la chemise. Se protéger les oreilles
contre le bruit. Utiliser le masque de
soudage avec le filtre ayant le bon indice
de protection.
S’entraîner. Seul le personnel qualifié doit
faire fonctionner cet équipement. Utiliser
les torches prescrites dans le manuel.
Tenir le personnel non qualifié et les
enfants à l’écart.
Ne pas enlever, détruire ou couvrir cette
étiquette. La remplacer si elle est
manquante, endommagée ou usée.
Hypertherm
SÉCURITÉ
INFORMATION SUR LE DÉPOUSSIÉRAGE
À certains endroits, la poussière peut représenter un risque d’explosion potentiel. À certains endroits, la poussière peut
représenter un risque d’explosion potentiel.
La norme NFPA 68 de la National Fire Protection Association des É.-U. (édition 2007) « Explosion Protection by
Deflagration Venting » établit les exigences relatives à la conception, à l’emplacement, à l’installation, à l’entretien et
à l’utilisation de dispositifs et de systèmes pour évacuer à l’air libre les gaz de combustion et les pressions après une
éventuelle déflagration. Communiquer avec le fabricant ou avec l’installateur pour tout système de dépoussiérage afin de
connaître les exigences applicables avant d’installer un tel système neuf ou d’apporter des modifications importantes aux
procédés ou aux matériaux utilisés à un système de dépoussiérage existant.
Consultez l’autorité compétente locale pour déterminer si une édition de la NFPA 68 a été adoptée par référence dans vos
codes du bâtiment locaux.
Voir le document NFPA68 pour obtenir des définitions et des explications des termes réglementaires tels que
« déflagration, autorité compétente, adopté par référence, valeur du pire cas, indice de déflagration » et autres termes.
Note 1 – L’interprétation d’Hypertherm de ces nouvelles exigences est que, sauf évaluation particulière du site, pour
déterminer que toute la poussière produite n’est pas combustible, l’édition 2007 de la NFPA 68 exige l’utilisation d’évents
d’explosion conçus pour la valeur du pire des cas (voir annexe F) qui pourrait provenir de la poussière de sorte que l’on
puisse concevoir la dimension et le type d’évent d’explosion. La NFPA 68 ne stipule pas particulièrement le procédé de
coupage plasma particulier ou autres procédés de coupage thermique comme le prescrivent ces nouveaux règlements
à tous les systèmes de dépoussiérage.
Note 2 – Les utilisateurs des manuels d’Hypertherm doivent consulter tous les règlements et lois fédéraux et locaux
applicables et s’y conformer. Hypertherm n’a pas l’intention, en publiant un manuel d’Hypertherm, de demander des
mesures qui ne sont pas conformes aux règlements et normes applicables et ce manuel ne peut jamais être interprété
dans ce sens.
Hypertherm
1a-11
11/08
SÉCURITÉ
1a-12
11/08
Hypertherm
Seccíon 1b
SEGURIDAD
En esta sección:
Reconocimiento de información de seguridad ..........................................................................................1b-2
Siga las instrucciones de seguridad ............................................................................................................1b-2
Los cortes pueden provocar incendios o explosiones ............................................................................1b-2
El choque eléctrico puede provocar la muerte..........................................................................................1b-3
Electricidad estática puede dañar tablillas de circuito ............................................................................1b-3
Humos tóxicos pueden causar lesiones o muerte....................................................................................1b-4
El arco de plasma puede causar lesiones y quemaduras.......................................................................1b-5
Los rayos del arco pueden producir quemaduras en los ojos y en la piel ..........................................1b-5
Seguridad de toma a tierra.............................................................................................................................1b-6
Seguridad de los equipos de gas comprimido..........................................................................................1b-6
Los cilindros de gas pueden explotar si están dañados .........................................................................1b-6
El ruido puede deteriorar la audición ...........................................................................................................1b-7
Operación de marcapasos y de audífonos.................................................................................................1b-7
Un arco plasma puede dañar tubos congelados ......................................................................................1b-7
Símbolos y marcas ...........................................................................................................................................1b-8
Etiquetas de advertencia ................................................................................................................................1b-9
Información sobre la colección de polvo seco........................................................................................1b-11
Hypertherm
1b-1
11/08
SEGURIDAD
RECONOCIMIENTO DE
INFORMACIÓN DE SEGURIDAD
Los símbolos que se muestran en esta sección se
utilizan para identificar los posibles peligros. Cuando vea
un símbolo de seguridad en este manual o en su máquina,
recuerde que existe la posibilidad de que se produzcan
lesiones personales y siga las instrucciones correspondientes
para evitar el peligro.
SIGA LAS INSTRUCCIONES
DE SEGURIDAD
Lea atentamente todos los mensajes de seguridad
de este manual y las etiquetas de seguridad en su máquina.
• Mantenga las etiquetas de seguridad de su máquina en
buen estado. Reemplace las etiquetas que se pierdan
o se dañen inmediatamente.
• Aprenda a utilizar la máquina y a utilizar los controles de la
manera correcta. No permita que sea utilizada por alguien
que no conozca su funcionamiento.
• Mantenga su máquina en buenas condiciones de
funcionamiento. La realización de modificaciones no
autorizadas a la máquina puede comprometer la seguridad
y la vida útil de la máquina.
PELIGRO
ADVERTENCIA
PRECAUCIÓN
Hypertherm usa las directivas del Instituto Americano de
Normas Nacionales (American National Standards Institute)
para las palabras y símbolos que señalan seguridad. Las
palabras PELIGRO y ADVERTENCIA se utilizan
conjuntamente con un símbolo de seguridad. La palabra
PELIGRO se utiliza para identificar los mayores peligros.
• Encontrará etiquetas de seguridad con las inscripciones
PELIGRO y ADVERTENCIA en su máquina, junto a peligros
específicos.
• Los mensajes de seguridad de PELIGRO preceden
instrucciones relacionadas en el manual que resultarán en
lesión grave o muerte si no se las sigue correctamente.
• En este manual, la palabra ADVERTENCIA va seguida de
instrucciones que, si no se siguen correctamente, pueden
provocar lesiones e inclusive la muerte.
• Los mensajes de seguridad de CUIDADO o PRECAUCIÓN
preceden mensajes relacionados con instrucciones en el
manual que puede resultar en lesiones menores, o daño
a equipo, si no se siguen correctamente.
LOS CORTES PUEDEN PROVOCAR INCENDIOS
O EXPLOSIONES
Prevención ante el fuego
• Asegúrese de que el área sea segura antes de proceder
a cortar. Tenga a mano un extinguidor de incendios.
• Retire todos los materiales inflamables, colocándolos
a por lo menos 10 metros del área de corte.
• Remoje los metales calientes o permita que se enfríen
antes de que entren en contacto con materiales
combustibles.
• Nunca corte depósitos que contengan materiales
inflamables – primero es necesario vaciarlos y limpiarlos
debidamente.
• Antes de realizar cortes en atmósferas potencialmente
inflamables, asegúrese de ventilar bien.
• Al realizar cortes utilizando oxígeno como gas plasma,
se requiere tener un sistema de ventilación de escape.
Prevención ante explosiones
• No corte en atmósferas que contengan polvo o vapores
explosivos.
• No corte depósitos o tubos a presión ni cualquier
depósito cerrado.
• No corte depósitos que hayan contenido materiales
combustibles.
1b-2
11/08
ADVERTENCIA
Peligro de explosión
Argón-Hidrógeno y metano
El hidrógeno y el metano son gases inflamables que
suponen un peligro de explosión. Mantenga el fuego lejos
de los cilindros y las mangueras que contengan mezclas
de hidrógeno o metano. Mantenga la llama y las chispas
lejos de la antorcha al utilizar metano o argón-hidrógeno
como plasma.
ADVERTENCIA
Detonación de hidrógeno con
el corte de aluminio
• Al cortar aluminio bajo agua o con agua en contacto con
el lado inferior del aluminio, puede acumularse gas
hidrógeno bajo la pieza a cortar y detonar durante la
operación de corte por plasma.
• Instale un múltiple de aireación en el fondo de la mesa
de agua para eliminar la posibilidad de la detonación
del hidrógeno. Consulte la sección del apéndice de
este manual para conocer detalles acerca del múltiple
de aireación.
Hypertherm
SEGURIDAD
EL CHOQUE ELÉCTRICO PUEDE PROVOCAR LA MUERTE
El contacto directo con piezas eléctricas conectadas puede
provocar un electrochoque fatal o quemaduras graves.
• Al hacer funcionar el sistema de plasma, se completa un
circuito eléctrico entre la antorcha y la pieza a cortar. La
pieza a cortar es una parte del circuito eléctrico, como
también cualquier cosa que se encuentre en contacto
con ella.
• Nunca toque el cuerpo de la antorcha, la pieza a cortar
o el agua en una mesa de agua cuando el sistema de
plasma se encuentre en funcionamiento.
Prevención ante el electrochoque
Todos los sistemas por plasma de Hypertherm usan alto
voltaje en el proceso de corte (son comunes los voltajes
CD de 200 a 400). Tome las siguientes precauciones
cuando se utiliza el equipo de plasma:
• Use guantes y botas aislantes y mantenga el cuerpo
y la ropa secos.
• No se siente, se pare o se ponga sobre cualquier
superficie húmeda cuando esté trabajando con el equipo.
• Aíslese eléctricamente de la pieza a cortar y de la tierra
utilizando alfombrillas o cubiertas de aislamiento secas
lo suficientemente grandes como para impedir todo
contacto físico con la pieza a cortar o con la tierra. Si su
única opción es trabajar en una área húmeda o cerca de
ella, sea muy cauteloso.
• Instale un interruptor de corriente adecuado en cuanto
a fusibles, en una pared cercana a la fuente de energía.
Este interruptor permitirá al operador desconectar
rápidamente la fuente de energía en caso de emergencia.
• Al utilizar una mesa de agua, asegúrese de que ésta se
encuentre correctamente conectada a la toma a tierra.
• Instale este equipo y conéctelo a tierra según el manual
de instrucciones y de conformidad con los códigos
locales y nacionales.
• Inspeccione el cordón de alimentación primaria con
frecuencia para asegurarse de que no esté dañado
ni agrietado. Si el cordón de alimentación primaria está
dañado, reemplácelo inmediatamente. Un cable
pelado puede provocar la muerte.
• Inspeccione las mangueras de la antorcha y
reemplácelas cuando se encuentren dañadas.
• No toque la pieza ni los recortes cuando se está
cortando. Deje la pieza en su lugar o sobre la mesa
de trabajo con el cable de trabajo conectado en
todo momento.
• Antes de inspeccionar, limpiar o cambiar las piezas de la
antorcha, desconecte la potencia primaria o desenchufe
la fuente de energía.
• Nunca evite o descuide los bloqueos de seguridad.
• Antes de retirar la cubierta de una fuente de energía
o del gabinete de un sistema, desconecte la potencia
primaria de entrada. Espere 5 minutos después de
desconectar la potencia primaria para permitir la
descarga de los condensadores.
• Nunca opere el sistema de plasma sin que las tapas de
la fuente de energía estén en su lugar. Las conexiones
expuestas de la fuente de energía presentan un serio
riesgo eléctrico.
• Al hacer conexiones de entrada, conecte el conductor
de conexión a tierra en primer lugar.
• Cada sistema de plasma Hypertherm está diseñado para
ser utilizado sólo con antorchas Hypertherm específicas.
No utilice antorchas diferentes, que podrían recalentarse
y ser peligrosas.
ELECTRICIDAD ESTÁTICA PUEDE DAÑAR TABLILLAS DE CIRCUITO
Use precauciones adecuadas cuando maneje tablillas
impresas de circuito
Hypertherm
• Almacene las tablillas PC en recipientes antiestáticos.
• Use la defensa de muñeca conectada a tierra cuando
maneje tablillas PC.
1b-3
11/08
SEGURIDAD
HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE
El arco plasma es por si solo la fuente de calor que se
usa para cortar. Según esto, aunque el arco de plasma
no ha sido identificado como la fuente de humo tóxico,
el material que se corta puede ser la fuente de humo
o gases tóxicos que vacían el oxígeno.
El humo producido varía según el metal que está
cortándose. Metales que pueden liberar humo tóxico
incluyen, pero no están limitados a, acero inoxidable,
acero al carbón, cinc (galvanizado), y cobre.
En algunos casos, el metal puede estar recubierto con
una sustancia que podría liberar humos tóxicos. Los
recubrimientos tóxicos incluyen, pero no están limitados
a, plomo (en algunas pinturas), cadmio (en algunas
pinturas y rellenos), y berilio.
Los gases producidos por el corte por plasma varían
basándose en el material a cortarse y el método de
cortar, pero pueden incluir ozono, óxidos de nitrógeno,
cromo hexavalente, hidrógeno, y otras substancias, si
están contenidas dentro o liberadas por el material que
se corta.
Se debe tener cuidado de minimizar la exposición del
humo producido por cualquier proceso industrial. Según
la composición química y la concentración del humo (al
igual que otros factores, tales como ventilación), puede
haber el riesgo de enfermedad física, tal como defectos
de natividad o cáncer.
Es la responsabilidad del dueño del equipo y instalación
el comprobar la calidad de aire en el lugar donde se está
usando el equipo para garantizar que la calidad del aire
en el lugar de trabajo cumpla con todas las normas y
reglamentos locales y nacionales.
1b-4
11/08
El nivel de la calidad del aire en cualquier lugar de trabajo
relevante depende en variables específicas al sitio tales
como:
• Diseño de mesa (mojada, seca, bajo agua).
• La composición del material, el acabado de la
superficie, y la composición de los recubrimientos.
• Volumen que se quita del material.
• La duración del corte o ranura.
• Tamaño, volumen del aire, ventilación y filtración del
lugar de trabajo.
• Equipo de protección personal.
• Número de sistemas de soldar y cortar en la operación.
• Otros procesos del lugar que pueden producir humo.
Si el lugar de trabajo debe cumplir reglamentos
nacionales o locales, solamente el monitoreo o las
pruebas que se hacen en el lugar pueden determinar si
el sitio está encima o debajo de los niveles permitidos.
Para reducir el riesgo de exposición a humo:
• Quite todos los recubrimientos y solventes del metal
antes de cortar.
• Use ventilación extractora local para quitar humo
del aire.
• No inhale el humo. Use un respirador con fuente propia
de aire cuando corte cualquier metal recubierto con,
o sospechado de contener, elementos tóxicos.
• Garantice que aquéllos usando equipo de soldar
o cortar, al igual que aparatos de respiración con aire
propio de aire, estén capacitados y entrenados en el
uso apropiado de tal equipo.
• Nunca corte recipientes con materiales potencialmente
tóxicos adentro. Primero, vacíe y limpie el recipiente
adecuadamente.
• Monitoree o compruebe la calidad del aire en el sitio
como fuera necesario.
• Consulte con un experto local para realizar un plan
al sitio para garantizar la calidad de aire seguro.
Hypertherm
SEGURIDAD
EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS
Antorchas de encendido instantáneo
El arco de plasma se enciende inmediatamente después
de activarse el interruptor de la antorcha.
El arco de plasma puede cortar a través de guantes y
de la piel con rapidez.
• Manténgase alejado de la punta de la antorcha.
• No sostenga el metal junto al trayecto de corte.
• Nunca apunte la antorcha hacia Ud. mismo o hacia
otras personas.
LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS
OJOS Y EN LA PIEL
Protección para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles (ultravioleta
e infrarrojo) que pueden quemar los ojos y la piel.
• Utilice protección para los ojos de conformidad con los códigos locales o nacionales aplicables.
• Colóquese protectores para los ojos (gafas o anteojos protectores con protectores laterales, y bien un casco de
soldar) con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco.
Protección para la piel Vista ropa de protección para proteger la piel contra quemaduras causadas por la radiación
ultravioleta de alta intensidad, por las chispas y por el metal caliente:
• Guantes largos, zapatos de seguridad y gorro.
• Roipa de combustión retardada y que cubra todas las partes expuestas.
• Pantalones sin dobladillos para impedir que recojan chispas y escorias.
• Retire todo material combustible de los bolsillos, como encendedores a butano e inclusive cerillas, antes de
comenzar a cortar.
Área de corte Prepare el área de corte para reducir la reflexión y la transmisión de la luz ultravioleta:
• Pinte las paredes y demás superficies con colores oscuros para reducir la reflexión.
• Utilice pantallas o barreras protectoras para proteger a los demás de los destellos.
• Advierta a los demás que no debe mirarse el arco. Utilice carteles o letreros.
Corriente de
arco (amps.)
El número de matiz
protector mínimo
(ANSI Z49.1:2005)
Menos de 40 A
41 a 60 A
61 a 80 A
81 a 125 A
126 a 150 A
151 a 175 A
176 a 250 A
251 a 300 A
301 a 400 A
401 a 800 A
5
6
8
8
8
8
8
8
9
10
Hypertherm
El número de matiz
sugerido para
comodidad
(ANSI Z49.1:2005)
5
6
8
9
9
9
9
9
12
14
OSHA 29CFR
1910.133(a)(5)
Europa
EN168:2002
8
8
8
8
8
8
8
8
9
10
9
9
9
9
10
11
12
13
13
1b-5
11/08
SEGURIDAD
SEGURIDAD DE TOMA A TIERRA
Cable de trabajo La pinza del cable de trabajo debe
estar bien sujetada a la pieza y hacer un buen contacto
de metal a metal con ella o bien con la mesa de trabajo.
No conecte el cable con la parte que va a quedar
separada por el corte.
Mesa de trabajo Conecte la mesa de trabajo a una
buena toma de tierra, de conformidad con los códigos
eléctricos nacionales o locales apropiados.
SEGURIDAD DE LOS EQUIPOS DE GAS
COMPRIMIDO
• Nunca lubrique reguladores o válvulas de cilindros con
aceite o grasa.
• Utilice solamente cilindros, reguladores, mangueras y
conectores de gas correctos que hayan sido diseñados
para la aplicación específica.
Potencia primaria de entrada
• Asegúrese de que el alambre de toma a tierra del
cordón de alimentación está conectado al terminal
de tierra en la caja del interruptor de corriente.
• Si la instalación del sistema de plasma supone
la conexión del cordón de alimentación primaria
a la fuente de energía, asegúrese de conectar
correctamente el alambre de toma a tierra del cordón
de alimentación primaria.
• Coloque en primer lugar el alambre de toma a tierra
del cordón de alimentación primaria en el espárrago
luego coloque cualquier otro alambre de tierra sobre
el conductor de tierra del cable. Ajuste firmemente
la tuerca de retención.
• Asegúrese de que todas las conexiones eléctricas
están firmemente realizadas para evitar
sobrecalentamientos.
LOS CILINDROS DE GAS
PUEDEN EXPLOTAR SI
ESTÁN DAÑADOS
Los cilindros de gas contienen gas bajo alta presión.
Un cilindro dañado puede explotar.
• Manipule y utilice los cilindros de gas comprimido de
acuerdo con los códigos locales o nacionales aplicables.
• Mantenga todo el equipo de gas comprimido y las
piezas relacionadas en buen estado.
• No use nunca un cilindro que no esté de pie y bien
sujeto.
• Coloque etiquetas y códigos de color en todas las
mangueras de gas para identificar el tipo de gas que
conduce cada una. Consulte los códigos locales
o nacionales aplicables.
• Mantenga la tapa de protección en su lugar encima
de la válvula, excepto cuando el cilindro se encuentre
en uso o conectado para ser utilizado.
• No permita nunca el contacto eléctrico entre el arco
de plasma y un cilindro.
• No exponga nunca los cilindros a calor excesivo,
chispas, escorias o llamas.
• No emplee nunca martillos, llaves u otro tipo de
herramientas para abrir de golpe la válvula del cilindro.
1b-6
11/08
Hypertherm
SEGURIDAD
EL RUIDO PUEDE
DETERIORAR LA AUDICIÓN
La exposición prolongada al ruido propio de las
operaciones de corte y ranurado puede dañar la
audición.
• Utilice un método de protección de los oídos
aprobado al utilizar el sistema de plasma.
• Advierta a las demás personas que se encuentren en
las cercanías acerca del peligro que supone el ruido
excesivo.
OPERACIÓN DE
MARCAPASOS Y DE
AUDÍFONOS
Los campos magnéticos producidos por las elevadas
corrientes pueden afectar la operación de marcapasos
y de audífonos.
Las personas que lleven marcapasos y audífonos
deberán consultar a un médico antes de acercarse
a sitios donde se realizan operaciones de corte
y ranurado por plasma.
Para reducir los peligros de los campos magnéticos:
• Mantenga el cable de trabajo y la manguera de la
antorcha a un lado, lejos del cuerpo.
UN ARCO PLASMA
PUEDE DAÑAR TUBOS
CONGELADOS
Se puede hacer daño a los tubos congelados, o se los
puede reventar, si uno trata de descongelarlos con una
antorcha por plasma.
Hypertherm
• Dirija la manguera antorcha lo más cerca posible
del cable de trabajo.
• No envuelva el cable de trabajo ni la manguera de
la antorcha en su cuerpo.
• Manténgase tan lejos de la fuente de energía como
sea posible.
1b-7
11/08
SEGURIDAD
SÍMBOLOS Y MARCAS
Su producto de Hypertherm puede tener una o más de las marcas que siguen en, o cerca de la placa de datos. Debido
a diferencias y conflictos en reglamentos nacionales, no todas las marcas se aplican a toda versión del producto.
Símbolo de marca S
El símbolo de marca S indica que la fuente de energía y antorcha son aptas para operaciones que se llevan
a cabo en entornos con peligro aumentado de choque o descarga eléctrica según IEC 60974-1.
Marca CSA
Los productos de Hypertherm con la marca CSA cumplen con los reglamentos de Estados Unidos y
Canadá para la seguridad del producto. Estos productos fueron evaluados, comprobados, y certificados por
CSA-Internacional. Alternativamente, el producto puede tener la marca según uno de los otros Laboratorios de
Prueba Reconocidos nacionalmente (NRTL siglas en inglés) acreditados en ambos Estados Unidos y Canadá,
tales como Underwriters Laboratories, Incorporated (UL) ó TÜV.
Marcas CE
Las marcas CE significan una declaración del fabricante de conformidad a las directivas y estándares aplicables
Europeos. Sólo aquellas versiones del producto Hypertherm con la marca CE ubicada en o cerca de la placa
de datos han sido comprobadas para cumplir con la Directiva Europea de Voltaje Bajo, la Compatibilidad
Electromagnético Europea (EMC). Los filtros EMC que necesitan cumplir con la Directiva Europea EMC están
incorporados dentro de las versiones del producto con la marca CE.
Marca GOST-R
Las versiones de los productos Hypertherm CE que incluye la marca de conformidad GOST-R cumplen con
la seguridad del productos y los requisitos EMC para exportarse a la Federación Rusa.
Marca c-Tick
Las versiones CE de los productos Hypertherm con la marca c-Tick cumple con los reglamentos EMC
requeridos para venta en Australia y Nueva Zelandia.
Marca CCC
La marca de Certificación Obligatoria China (CCC en inglés) indica que el producto ha sido comprobado y se
lo ha encontrado que cumple con los reglamentos de seguridad del producto requeridos para venta en China.
1b-8
11/08
Hypertherm
SEGURIDAD
ETIQUETA DE ADVERTENCIA
Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. Es importante que el
operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia
según se describen. El texto numerado corresponde a los cuadros numerados de la etiqueta.
WARNING
AVERTISSEMENT
ou un incendie.
endommagés.
Las chispas producidas por el corte pueden causar
explosiones o incendios.
1.
3.3 Antes de trabajar en una máquina, desconecte
el enchufe de entrada o la potencia primaria.
1.1 Mantenga los materiales inflamables lejos del lugar
de corte.
4.
1.2 Tenga a mano un extinguidor de incendios y asegúrese
de que alguien esté preparado para utilizarlo.
4.1 Mantenga la cabeza fuera de los gases tóxicos.
La inhalación de los humos provenientes del área
de corte puede ser nociva para la salud.
1.3 No corte depósitos cerrados.
4.2 Utilice ventilación forzada o un sistema local de escape
para eliminar los humos.
2.
4.3 Utilice un ventilador para eliminar los humos.
El arco de plasma puede causar quemaduras y lesiones.
2.1 Apague la fuente de energía antes de desarmar
la antorcha.
5.
2.2 No sostenga el material junto al trayecto de corte.
5.1 Utilice un sombrero y gafas de seguridad. Utilice
protección para los oídos y abróchese el botón del
cuello de la camisa. Utilice un casco de soldar con
el filtro de sombreado adecuado. Proteja su cuerpo
completamente.
2.3 Proteja su cuerpo completamente.
3.
Los electrochoques provocados por la antorcha
o el cableado pueden ser fatales. Protéjase del
electrochoque.
3.1 Colóquese guantes aislantes. No utilice guantes
dañados o mojados.
3.2 Aíslese de la pieza de trabajo y de la tierra.
Hypertherm
Los rayos del arco pueden producir quemaduras en los
ojos y en la piel.
6.
Antes de trabajar en la máquina o de proceder a cortar,
capacítese y lea las instrucciones completamente.
7.
No retire las etiquetas de advertencia ni las cubra con
pintura.
1b-9
11/08
SEGURIDAD
ETIQUETA DE ADVERTENCIA
1.
Esta etiqueta de advertencia se encuentra adherida a la fuente de
energía. Es importante que el operador y el técnico de mantenimiento
comprendan el sentido de estos símbolos de advertencia según se
describen. El texto numerado corresponde a los cuadros numerados
de la etiqueta.
1.1
1.2
1.3
2.
2.1
2.2
2.3
3.
3.1
3.2
3.3
4.
4.1
4.2
4.3
5.
5.1
110647 Rev. A
6.
7.
1b-10
11/08
Las chispas producidas por el corte
pueden causar explosiones o incendios.
Mantenga los materiales inflamables
lejos del lugar de corte.
Tenga a mano un extinguidor de
incendios y asegúrese de que alguien
esté preparado para utilizarlo.
No corte depósitos cerrados.
El arco de plasma puede causar
quemaduras y lesiones.
Apague la fuente de energía antes
de desarmar la antorcha.
No sostenga el material junto al trayecto
de corte.
Proteja su cuerpo completamente.
Los electrochoques provocados por
la antorcha o el cableado pueden ser
fatales. Protéjase del electrochoque.
Colóquese guantes aislantes. No utilice
guantes dañados o mojados.
Aíslese de la pieza de trabajo y de la tierra.
Antes de trabajar en una máquina,
desconecte el enchufe de entrada
o la potencia primaria.
La inhalación de los humos provenientes
del área de corte puede ser nociva para
la salud.
Mantenga la cabeza fuera de los gases
tóxicos.
Utilice ventilación forzada o un sistema
local de escape para eliminar los humos.
Utilice un ventilador para eliminar los
humos.
Los rayos del arco pueden producir
quemaduras en los ojos y en la piel.
Utilice un sombrero y gafas de
seguridad. Utilice protección para los
oídos y abróchese el botón del cuello
de la camisa. Utilice un casco de soldar
con el filtro de sombreado adecuado.
Proteja su cuerpo completamente.
Antes de trabajar en la máquina
o de proceder a cortar, capacítese
y lea las instrucciones completamente.
No retire las etiquetas de advertencia
ni las cubra con pintura.
Hypertherm
SEGURIDAD
INFORMACIÓN SOBRE LA COLECCIÓN DE POLVO SECO
En algunos sitios, el polvo seco puede representar un peligro potencial de explosión.
La edición del 2007 de “U.S. National Fire Protection Association” iniciales en inglés NFPA (La Asociación Americana
Nacional de Protección Contra Incendios) del estándar 68 “Protección de Explosión por medio de Respiradero de
Deflagración” proporciona requisitos para el diseño, ubicación, instalación, mantenimiento, y uso de aparatos y sistemas
para dar salida a gases de combustión y presiones después de todo evento de deflagración. Consulte con el fabricante
o instalador de cualquier sistema de colección de polvo seco para los requisitos aplicables antes de que instale un
sistema nuevo de colección de polvo seco, o haga cambios significativos en el proceso o materiales que se usen con
un sistema existente de colección de polvo seco.
Consulte su “Autoridad que Tenga Jurisdicción” (iniciales en inglés AHJ) local para determinar si cualquier edición
de la NFPA 68 ha sido “adoptada por referencia” en los códigos de construcción locales.
Remítase a la NFPA 68 para definiciones y explicaciones de los términos reguladores como “deflagración, AHJ, adoptada
por referencia, el valor Kst, índice de deflagración” y otros términos.
Nota 1 – La interpretación de Hypertherm de estos nuevos requisitos es que, a no ser que se haya completado una
evaluación específica del sitio para determinar que todo polvo generado no es combustible, la edición del 2007 de
la NFPA 68 requiere el uso de respiraderos de explosión diseñados para el peor caso del valor Kst (vea anexo F) que
pudiera ser generado por el polvo, de manera que el tamaño y tipo del respiradero de explosión pueda diseñarse.
La NFPA 68 no identifica específicamente corte por plasma u otros procesos de cortes termales como si requirieran
sistemas de respiraderos de deflagración, pero en realidad aplica estos nuevos requisitos a todos los sistemas de
colección de polvos secos.
Nota 2 – Los usuarios de los manuales de Hypertherm deberían consultar y cumplir con todas las leyes y reglamentos
federales, estatales y locales aplicables. Hypertherm, al publicar todo manual de Hypertherm, no intenta urgir acción
que no esté en cumplimiento con todos los reglamentos y normas, y este manual nunca debe interpretarse como
si lo hiciera así.
Hypertherm
1b-11
11/08
SEGURIDAD
1b-12
11/08
Hypertherm
PMX30_OM_02.qxp:PMX30_OM_02.qxd
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Page 2-1
Section 2
SPECIFICATIONS
In this section:
System description .............................................................................................................................................2-2
Power supply dimensions and weight............................................................................................................2-2
Power supply ratings .........................................................................................................................................2-3
Torch dimensions ................................................................................................................................................2-4
T30v torch ratings...............................................................................................................................................2-4
mark ......................................................................................................................................................2-5
CE mark ......................................................................................................................................................2-5
IEC symbols...............................................................................................................................................2-5
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Page 2-2
SPECIFICATIONS
System description
The Powermax30 is a highly portable, 30-amp, hand-held plasma cutting system appropriate for a
wide range of applications.
The standard Powermax30 includes one complete set of the consumables needed for cutting
(retaining cap, swirl ring, nozzle, electrode), a spare electrode, a spare nozzle, an air fitting reducer
(1/4 FPT x 1/8 NPT), a consumables holder, an Operator Manual, and a Quick Setup Card. The
Powermax30 with the deluxe carrying case includes 3 spare electrodes, 3 spare nozzles, a
retaining cap, a swirl ring, a deflector, silicone lubricant, 3 o-rings, gloves, a circle cutting guide,
and a carrying strap in addition to the consumables holder, air fitting reducer, Operator Manual, and
Quick Setup Card.
The power cords on the CSA units have a quick disconnect adapter and are shipped with a
120V/15A (NEMA 5-15P) plug and a 240V/20A (NEMA 6-50P) plug in addition to the twist-lock
240V/20A (NEMA L6-20P) plug wired to the system. The CE units are shipped without a plug on
the power cord. See Section 3, Power cord considerations, for more information.
You can order additional consumables and accessories – such as the carrying case, carrying strap,
and circle cutting guide – from any Hypertherm distributor. See Section 5, Maintenance and Parts,
for a list of spare and optional parts.
Power supply dimensions and weight
13"
(330 mm)
5.5"
(140 mm)
20.65 lb
9.37 kg
10.0"
(267 mm)
11.5"
(292.1 mm)
Weight includes the hand torch
and 15 ft (4.57 m) lead.
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Page 2-3
SPECIFICATIONS
Power supply ratings
Rated open-circuit voltage (U0)
240 VDC
Rated output current (I2)
15 A to 30 A
Rated output voltage (U2)
83 VDC
Duty cycle at 40° C, U1=120 VAC
(See data plate on power supply for
more information on duty cycle.)
35 % (I2=30 A, U2=83 V)
60 % (I2=23 A, U2=83 V)
100 % (I2=18 A, U2=83 V)
Duty cycle at 40° C, U1=200–240 VAC
50 % (I2=30 A, U2=83 V)
75 % (I2=24 A, U2=83 V)
100 % (I2=21 A, U2=83 V)
Operating temperature
14° to 104° F (-10° to 40° C)
Storage temperature
-13° to 131° F (-25° to 55° C)
Power factor (120 V – 240 V)
0.99 – 0.97
Input voltage (U1)/ Input current (I1) at
rated output (U2 MAX, I2 MAX)
Gas type
Gas quality
Minimum required gas inlet pressure
and flow
Recommended gas inlet flow
and flow
120 V / 26 A
200-240 V / 15,5-13 A
Air
Nitrogen
Clean, dry, oil-free
99.995 % pure
3.5 scfm @ 65 psi (99.1 l/min @ 4.5 bar
4.0 scfm @ 80 psi (113.3 l/min @ 5.5 bar)
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Page 2-4
SPECIFICATIONS
Torch dimensions
8.72" ( 221 mm)
8.5" (216 mm)
1.58"
(40 mm)
3.10"
(79 mm)
2.00" (50 mm)
1.00"
(25 mm)
T30v torch ratings
Recommended capacity
1/4 inch (6 mm) at 30 A (35% duty cycle)
Maximum capacity
Severance capacity
Weight
2-4
2.1 lbs (1.0 kg)
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Page 2-5
SPECIFICATIONS
Symbols and markings
S mark
The
mark indicates that the power supply and torch are suitable for use in environments with
increased hazard of electrical shock.
CE mark
The CE mark (
) constitutes a manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of Hypertherm products with a CE mark located on
or near the data plate have been tested for compliance with the European Low Voltage Directive
and the European EMC Directive. EMC filters needed to comply with the European EMC Directive
are incorporated within versions of the power supply with a CE mark.
IEC symbols
The following symbols may appear on the power supply data plate, control labels, switches,
and LEDs:
Direct current (DC)
1~
f1
An inverter-based power
source
f2
Alternating current
(AC)
Plasma torch
cutting
AC input power
connection
The terminal for the
external protective
(earth) conductor
l
O
Volt/amp curve, “drooping”
characteristic
AC
Power is ON (LED)
Inlet gas pressure is low
Missing or loose
consumables
Power is ON
Power is OFF
Power supply is
overheated
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Page 2-6
SPECIFICATIONS
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Page 3-1
Section 3
SETUP
In this section:
Unpack the Powermax30 ..................................................................................................................................3-2
Claims .........................................................................................................................................................3-2
Contents .....................................................................................................................................................3-2
Position the power supply.................................................................................................................................3-3
Voltage configurations .......................................................................................................................................3-3
Requirements for grounding.............................................................................................................................3-3
Power cord considerations...............................................................................................................................3-4
Power cord and plugs for CSA power supplies ...............................................................................3-4
Power cord for CE power supplies ......................................................................................................3-5
Extension cord recommendations ........................................................................................................3-6
Generator recommendations .................................................................................................................3-6
Gas supply............................................................................................................................................................3-7
Connection.................................................................................................................................................3-7
Additional gas filtration............................................................................................................................3-8
powermax30
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Page 3-2
SETUP
Unpack the Powermax30
1. Verify that all items on your order have been received in good condition. Contact your distributor
if any parts are damaged or missing.
2. Inspect the power supply for damage that may have occurred during shipping. If there is
evidence of damage, refer to Claims, below. All communications regarding this equipment must
include the model number and serial number located on the bottom of the power supply.
3. Before you set up and operate this Hypertherm system, read Section 1, Safety.
Claims
• Claims for damage during shipment – If your unit was damaged during shipment,
you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill
of lading upon request. If you need additional assistance, call the nearest Hypertherm office
listed in the front of this manual.
• Claims for defective or missing merchandise – If any component is missing or
defective, contact your Hypertherm distributor. If you need additional assistance, call
the nearest Hypertherm office listed in the front of this manual.
Contents
Verify the items in the box against the illustration.
Note:
If you purchased the Powermax30 with the deluxe carrying case, your package will include
the case, 3 electrodes, 3 nozzles, a swirl ring, a retaining cap, a deflector, silicone
lubricant, 3 o-rings, gloves, and a plasma cutting guide in addition to the consumables
holder, air fitting reducer (1/4 FPT x 1/8 NPT), Operator Manual, Quick Setup Card, and
Product Registration Card.
Strap
(CSA)
Operator Manual
or
(CE)
Quick Setup Card
1
1
Product Registration
Consumables
holder
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Page 3-3
SETUP
Position the power supply
Locate the Powermax30 power supply near a 120 volt or 230 volt power receptacle. Allow at least
10 inches (0.25 m) of space at the front and back of the power supply for proper ventilation.
Voltage configurations
The Powermax30 power supply automatically selects either 120 volts or 230 volts, as appropriate.
The maximum output voltage will vary based on your input voltage and the circuit’s amperage. The
following chart shows the maximum rated output for typical combinations of input voltage and
amperage. Input voltages can be ±10%.
Rated output
Amps (RMS) input
at rated output, 60
Hz, single-phase
KVA
120 V, 15 A circuit
20 A, 83 V
17
2.1
120 V, 20 A circuit
30 A, 83 V
26
3.1
120 V, 30 A circuit
30 A, 83 V
26
3.1
200-240 V, 20A
circuit
30 A, 83 V
15.5 – 13
3.0
Input voltage
Caution:
A circuit capable of 15 amps, 120 V or 20 amps, 230 V is required
for proper operation. Protect the circuit with appropriately sized
time-delay fuses or circuit breakers.
Requirements for grounding
To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the
Powermax30 must be properly grounded:
• The power supply must be grounded through the power cord according to national and local
electrical codes:
• Single-phase service must be of the 3-wire type with a green or green/yellow wire for the
protective earth ground. Do not use a 2-wire service.
• Refer to Section 1, Grounding Safety, for more information.
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Operator Manual
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Page 3-4
SETUP
Power cord considerations
Powermax30 power supplies are shipped with CSA and CE power cord configurations.
Power cord and plugs for CSA power supplies
The power cords on the CSA power supplies are shipped with a 120V/15A (NEMA 5-15P) plug
adapter and a 240V/20A (NEMA 6-50P) plug adapter in addition to the twist-lock 240V/20A
(NEMA L6-20P) plug wired to the system. A 120V/20A plug adapter is available as an accessory.
See Section 5, Powermax30 accessory parts, for part number information.
• The power cord on the Powermax30 power
supply is equipped with a twist-lock plug
(NEMA L6-20P) appropriate for use on a
240V/20A circuit with a twist-lock outlet.
• To operate the Powermax30 on a lower
amperage circuit, attach the female end of the
120V/15A (NEMA 5-15P) plug adapter to
the power supply's twist-lock plug.
Note:
Do not set the amperage adjustment
knob above 20A or your circuit
breaker may trip. See Section 4,
Power on the system, for more
information.
• To operate the Powermax30 on a 240V/20A
circuit, attach the female end of the
240V (NEMA 6-50P) plug to the power
supply's twist-lock plug.
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Page 3-5
SETUP
Power cord for CE power supplies
The CE power supplies are shipped without a plug on the power cord. To operate at 230 V, obtain
the correct plug and have it installed by a licensed electrician as shown below.
1 230 V plug
1
2 To line 1 terminal (brass)
2
3 To line 2 terminal (brass)
5
4 To ground terminal (green)
6
5 Outer shell
3
4
6 Cord grip
1. Strip back the cord insulation to separate wires 3, 4, and 5.
2. Remove each wire’s insulation in order to make good contact with the plug terminals.
3. Make the connections, reinstall the outer shell and cord grip, and tighten the cord grip’s
screws. Screws should be snug, but not overly tight.
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Page 3-6
SETUP
Extension cord recommendations
A
Use an extension cord of an appropriate wire size for the cord length and system voltage. Use a
cord that meets national and local codes.
A
Inputvoltage
120 VAC
200 – 240 VAC
Phase
Recommended
cord gauge size
Length
1
1
12 AWG
14 AWG
Up to 53 ft (16 m)
Up to 133 ft (40.5 m)
Generator recommendations
When using a generator with the Powermax30, it should produce 240 VAC.
Engine
drive rating
Output
current
Performance
5.5 KW
30 A
Full arc stretch
4 KW
25 A
Limited arc stretch
Powermax30 systems with serial numbers below 30-003132 may shut down and show an error
condition (all LEDs flash) when used with a generator that has a higher than normal voltage
(greater than 250 VAC). To avoid shutdown, check your generator’s voltage regulator for proper
operation.
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Page 3-7
SETUP
Gas supply
The gas supply for the Powermax30 can be shop-compressed or cylinder-compressed. A highpressure regulator must be used on either type of supply and must be capable of delivering gas to
the filter on the power supply at 3.5 scfm @ 65 psi (99.1 l/min @ 4.5 bar). To ensure adequate
pressure to the power supply, set the regulator to 80 to 100 psi (5.5 to 6.9 bar).
If gas supply quality is poor, cut speeds decrease, cut quality deteriorates, cutting thickness
capability decreases, and the life for consumables shortens.
WARNING
Do not allow the gas supply pressure to exceed 135 psi (9.3 bar). The filter bowl may
explode if this pressure is exceeded.
Connection
Connect the gas supply to the system using an inert gas hose with a 3/8 inch (9.5 mm) internal
diameter and a 1/4 NPT quick-disconnect coupler. The Powermax30 consumables kit includes a
1/4 FPT x 1/8 NPT air fitting reducer as well.
Caution:
Synthetic lubricants containing esters that are used in some air
compressors will damage polycarbonates used in the air
regulator bowl.
I
O
Optional reducer
80 – 100 psi (5.5 – 6.9 bar) gas supply
(maximum 135 psi or 9.3 bar)
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Operator Manual
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Page 3-8
SETUP
Additional gas filtration
When site conditions introduce moisture, oil or other contaminants into the gas line, use a threestage coalescing filtration system, such as the Eliminizer filter kit (part number 128647) available
from Hypertherm distributors. A three-stage filtering system works as shown below to clean
contaminants from the gas supply.
Water and particle filter
Gas supply
Oil filter
Oil vapor filter
Powermax30
The filtering system should be installed between the 1/4 NPT quick-disconnect coupler and the
power supply.
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Page 4-1
Section 4
OPERATION
In this section:
Controls and indicators .....................................................................................................................................4-2
Front controls and LEDs.........................................................................................................................4-2
Rear controls .............................................................................................................................................4-2
Install the consumables .....................................................................................................................................4-3
Attach the work clamp .......................................................................................................................................4-4
Power ON the system........................................................................................................................................4-4
Hand torch operation .........................................................................................................................................4-6
Safety trigger operation ..........................................................................................................................4-6
Hand torch cutting hints..........................................................................................................................4-7
To start a cut from the edge of the workpiece...................................................................................4-8
To pierce a workpiece..............................................................................................................................4-9
Cut chart.............................................................................................................................................................4-10
Duty cycle and overheating............................................................................................................................4-11
Common cutting faults ....................................................................................................................................4-11
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Page 4-2
OPERATION
Controls and indicators
The Powermax30 has an ON/OFF rocker switch, an amperage adjustment knob and 4 indicator
lights, which are described below.
Front
Rear
I
O
120V 15A
120V 20A
240V 20A
Front controls and LEDs
AC
Power ON LED (green)
When illuminated, this LED indicates
that the power switch has been set at I
(ON) and that the safety interlocks are
satisfied.
Temperature LED (yellow)
that the power supply temperature is
outside the acceptable operating
range.
Gas pressure LED (yellow)
that the gas pressure is below 40 psi
(2.8 bar). Correct this condition before
you continue.
Amps adjustment knob
Use this knob to set the output
current between 15 and 30 amps.
Torch cap LED (yellow)
that the consumables are loose,
improperly installed, or missing.
Some fault conditions will cause one or more of the LEDs to blink. For information on what these
fault conditions are and how to correct them, see Basic troubleshooting in Section 5.
Rear controls
I
O
4-2
ON (I)/OFF (O) power switch
Activates the power supply and its control circuits.
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Page 4-3
OPERATION
Install the consumables
WARNING
INSTANT-ON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
I
O
The plasma arc comes on immediately when the torch trigger is
activated. Make sure the power is OFF before changing consumables.
To operate the T30v torch, it must have a complete set of consumable parts installed: a retaining
cap, nozzle, swirl ring and electrode. You may also use an optional deflector.
With the power switch in the OFF (O) position, verify that the torch consumables are installed
as shown.
Electrode
Swirl ring
Nozzle
Retaining cap
Deflector (optional, only included
with the deluxe carrying case).
Tighten only
by hand.
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Operator Manual
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Page 4-4
OPERATION
Attach the work clamp
The work clamp must be attached to the workpiece while you are cutting. Ensure that the work
clamp and the workpiece make good metal-to-metal contact. Attach the work clamp as close as
possible to the area being cut to reduce exposure to electric and magnetic fields (EMF). Do not
attach the work clamp to the portion of the workpiece to be cut away.
Work clamp
Power ON the system
1. Set the ON/OFF rocker switch to the ON (I) position.
I
I
O
4-4
O
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Page 4-5
OPERATION
2. Adjust the amps knob to the desired cutting current based on the input voltage and circuit size.
To operate your Powermax30 system on a 120-volt, 15-amp circuit, do not set the amps higher
than 20 (the dark gray part of the dial). See Section 3, Voltage configurations, for more
information.
120V 15A
120V 20A
240V 20A
3. Verify that the green power ON LED on the front of the power supply is illuminated and that
none of the other LEDs are illuminated. If the gas pressure, temperature, or cap sensor LEDs
are illuminated or blinking, correct the fault condition before continuing. See Basic
troubleshooting in Section 5, for more information.
AC
When the power ON LED is illuminated, none of the other LEDs are illuminated or blinking, and
the amperage knob is set, the system is ready for use.
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Operator Manual
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Page 4-6
OPERATION
Hand torch operation
WARNING
INSTANT-ON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
Plasma arc comes on immediately when the torch trigger is activated.
The plasma arc will cut quickly through gloves and skin.
• Keep away from the torch tip.
• Do not hold the workpiece and keep your hands clear of the cutting path.
• Never point the torch toward yourself or others.
Safety trigger operation
The Powermax30 is equipped with a safety trigger to prevent accidental firings. When you are
ready to cut with the torch, flip the yellow safety trigger forward (toward the torch head) and press
the torch trigger as show below.
1
2
3
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Page 4-7
OPERATION
Hand torch cutting hints
• Drag the nozzle lightly along the workpiece.
• While cutting, make sure that sparks are exiting from the bottom of the workpiece.
• If sparks are spraying up from the workpiece, move the torch more slowly, or set the output
current higher.
• Hold the torch nozzle perpendicular to the
workpiece so that the nozzle is at a
90° angle to the cutting surface and watch
the arc as it cuts along the line.
• If you fire the torch unnecessarily, you
shorten the life of the nozzle and electrode.
• Pulling the torch along the cut is easier than
pushing it.
• For straight-line cuts, use a straight edge as
a guide. To cut circles, use a template or a
radius cutter attachment (a circle cutting
guide).
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Page 4-8
OPERATION
To start a cut from the edge of the workpiece
1. With the work clamp attached to the
workpiece, hold the torch nozzle
perpendicular to the edge of the
workpiece.
2. Press the torch trigger to start the arc.
Pause at the edge until the arc has cut
completely through the workpiece.
3. Drag the nozzle lightly across the
workpiece to proceed with the cut.
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Page 4-9
OPERATION
To pierce a workpiece
WARNING
KSPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN.
When firing the torch at an angle, sparks and hot metal will spray
out from the nozzle. Point the torch away from yourself and others.
1. With the work clamp attached to the workpiece, hold the torch at an angle to the workpiece
with the nozzle within 1/16 inch (1.5 mm) of it before firing the torch.
2. Fire the torch while still at an angle to
the workpiece, then slowly rotate the
torch to a perpendicular (90°)
position.
3. Hold the torch in place. When sparks
exit from the bottom of the workpiece,
the arc has pierced the material.
4. When the pierce is complete,
drag the nozzle lightly along the
workpiece to proceed with the cut.
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Operator Manual
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Page 4-10
OPERATION
Cut chart
The cut chart below is based on the use of 30-amp standard consumables and drag cutting.
Optional
deflector
Retaining cap
Nozzle
Swirl ring
Material thickness
T30v torch
Electrode
Maximum
cutting speed
Material
Arc
current
(A)
inches per
minute
millimeters
per minute
1,3
3,4
4,8
6,0
9,0
Mild steel
Mild steel
Mild steel
Mild steel
Mild steel
30
30
30
30
30
394
87
52
33
15
10007
2210
1321
838
381
18 ga.
10 ga.
1/4"
3/8"
1,3
3,4
6,0
9,0
Stainless steel
Stainless steel
Stainless steel
Stainless steel
30
30
30
30
221
55
24
11
5613
1397
610
279
18 ga.
10 ga.
1/4"
3/8"
1,3
3,4
6,0
9,0
Aluminum
Aluminum
Aluminum
Aluminum
30
30
30
30
399
78
26
11
10135
1981
660
279
gauge or
inches
millimeters
18 ga.
10 ga.
3/16"
1/4"
3/8"
* To cut material thicker than 1/4 inch (6 mm), start torch at edge of material.
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Page 4-11
OPERATION
Duty cycle and overheating
The duty cycle is the amount of time, in minutes, that a plasma arc can remain on within a
10-minute period when operating at an ambient temperature of 104° F (40° C). With a 120 V
input:
• At 30 A, the arc can remain on for 3.5 minutes out of 10 minutes without causing the unit to
overheat (35% duty cycle).
• At 23 A, the arc can remain on for 6 minutes out of 10 (60%).
• At 18 A, the arc can remain on for 10 minutes (100%).
With a 200-240 V input:
• At 30 A, the arc can remain on for 5 minutes out of 10 (50% duty cycle).
• At 24 A, the arc can remain on for 7.5 minutes out of 10 (75%).
• At 21 A, the arc can remain on for 10 minutes (100%).
If the power supply overheats because the duty cycle is exceeded, the temperature LED will
illuminate, the arc will shut off, and the cooling fan will continue to run. To resume cutting, wait for
the temperature LED to extinguish.
Common cutting faults
The torch does not cut completely through the workpiece. The causes can be:
• The cut speed is too fast.
• The consumables are worn.
• The metal being cut is too thick.
• The work clamp is not attached properly to the workpiece.
The arc sputters and consumables life is shorter than expected. The cause can be:
• Moisture in the gas supply.
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Operator Manual
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Page 4-12
OPERATION
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Page 5-1
Section 5
MAINTENANCE AND PARTS
In this section:
Routine maintenance..........................................................................................................................................5-2
Inspect the consumables ..................................................................................................................................5-3
Basic troubleshooting ........................................................................................................................................5-4
Repairs...................................................................................................................................................................5-7
Remove and replace the cover and Nomex® barrier .......................................................................5-7
Remove an endcap ..................................................................................................................................5-9
Disconnect the torch lead....................................................................................................................5-11
Replace the work lead ..........................................................................................................................5-13
Replace the power cord (CSA)..........................................................................................................5-15
Replace the power cord (CE) .............................................................................................................5-17
Replace the air filter element...............................................................................................................5-19
Replacement and accessory parts ...............................................................................................................5-20
Power cords and adapters...................................................................................................................5-20
Accessory parts......................................................................................................................................5-20
T30v hand torch assembly ..................................................................................................................5-21
Consumables ..........................................................................................................................................5-21
Filter regulator.........................................................................................................................................5-22
Work clamp .............................................................................................................................................5-22
Powermax30 labels ...............................................................................................................................5-23
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Page 5-2
Routine maintenance
DANGER
Disconnect the electrical power before you perform any maintenance.
All work that requires removal of the power supply cover must be
performed by a qualified technician.
Every use:
Inspect the consumables for
proper installation and wear.
AC
Check the indicator lights and
correct any fault conditions.
Every 3 months:
Inspect the trigger for damage. Inspect the
torch body for cracks and exposed wires.
Replace any damaged parts.
Replace any damaged labels.
Inspect the power cord and
plug. Replace if damaged.
Inspect the torch lead.
Replace if damaged.
Every 6 months:
or
5-2
0
Clean the inside of the power
supply with compressed air or a
vacuum.
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Page 5-3
Inspect the consumables
Part
Inspect
Action
The center hole for
roundness.
Deflector
Replace the deflector if the
hole is no longer round.
The gap between the
deflector and the nozzle for
accumulated debris.
Remove the deflector and
clean any material away.
The center hole for
roundness.
Nozzle
Electrode
o
o
Good
Worn
The center surface for wear
and verify the pit depth.
Replace if the center hole
is not round.
Replace if the surface is
worn or the pit depth is
greater than 1/16 inch (1.6
mm) deep.
Max. 1.6 mm
powermax30
Swirl ring
The internal surface for
damage or wear and the
gas holes for blockages.
Replace if the surface is
damaged or worn or any of
the gas holes are blocked.
Torch o-ring
The surface for damage,
wear, or a lack of
lubrication.
If the o-ring is dry, lubricate
it with a thin layer of
silicone lubricant. If it is
cracked or worn, replace it.
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Basic troubleshooting
The following table provides an overview of the most common problems that may arise when using
the Powermax30 and explains how to solve them.
If you are unable to fix the problem by following this basic troubleshooting guide or if you need
further assistance:
1. Call your Hypertherm distributor or authorized Hypertherm repair facility.
2. Call nearest Hypertherm office listed in the front of this manual.
Problem
Solution
The ON/OFF power switch is set to ON
(I), but the power ON LED is not
illuminated.
• Verify that the power cord is plugged into the
receptacle.
The power ON LED is illuminated and
the gas pressure LED is illuminated.
• Verify that the gas is turned on and the gas supply
line is connected to the power supply.
• Verify that the power is on at the main power
panel or at the disconnect-power switch box.
• Inspect the gas supply line for leaks and verify the
incoming gas pressure.
The power ON LED is blinking.
• The input line voltage has a variance that is
greater than ±15% of the rated voltage. Have an
electrical technician check the incoming power.
See Section 2, Specifications, for more
information.
the temperature LED is illuminated.
• Leave the power supply on to allow the fan to cool
the power supply.
• If the internal temperature of the power supply
approaches -22° F (-30° C), the temperature LED
may light. Move the power supply to a warmer
location.
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Problem
Solution
the torch cap LED is illuminated or
blinks.
• Turn OFF the power supply and tighten or install
the consumables. See Section 4, Install the
consumables.
If the consumables become loose or were
removed while the power supply is ON, turn OFF
the power supply, correct the problem and then
turn ON the power supply to clear this fault.
The gas pressure and temperature
LEDs blink when the system is
powered on.
• If the power supply is turned on while the torch
trigger is pressed, the system will be disabled.
Release the trigger and restart the power supply.
All LEDs blink when the system is
powered on or the torch is fired several
times in succession.
• All LEDs blinking indicates a major fault. A
qualified service technician must service the
system. Contact your distributor or use the
information in the front of this book to contact
Hypertherm Technical Service.
AC
Note: Using a generator with a Powermax30 system
that has a serial number below
30-003132 can cause the LEDs to blink if the
generator delivers a higher than normal
voltage. To correct the fault, disconnect the
Powermax30 from the generator and check
the generator’s voltage regulator.
The arc does not transfer to the
workpiece.
• Clean the area where the clamp contacts the
workpiece to ensure a good metal-to-metal
connection.
• Inspect the work clamp for damage and repair it if
necessary.
• The torch may be too far away from the workpiece.
Move the torch closer to the workpiece and fire
the torch again. See Section 4, Hand torch
operation.
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Problem
The arc blows out, but re-ignites when
the torch trigger is pressed again.
Solution
• Inspect and replace the consumable parts if they
are worn or damaged. See Inspect the
consumables, in this section.
• Replace the gas filter element inside the power
supply if it is contaminated. See Replace the air
filter element, in this section.
The arc sputters and hisses.
• The gas filter element inside the power supply is
contaminated. Replace the element – See
Replace the air filter element, in this section.
• Inspect the gas line for water. If necessary, install
or repair the gas filtration to the power supply.
See Section 3, Gas supply.
The cut quality is poor.
• Verify that the torch is being used correctly. See
Section 4, Hand torch operation.
• Inspect the consumables for wear and replace
as necessary. See Inspect the consumables, in
this section.
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Repairs
DANGER
Disconnect electrical power before performing any maintenance. All work
requiring removal of the power supply cover must be performed by a
qualified technician.
Remove and replace the cover and Nomex® barrier
The first step in most maintenance and repair procedures for the Powermax30 is removing the
cover and the Nomex barrier. To protect your power supply, it is important to replace both items
properly when the maintenance is complete.
Removal
1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.
2. Use a #2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power
supply. Tip the endcaps back slightly so that you can get the edges of the handle out from
underneath the endcaps. Set the handle screws aside and then lift the cover off the power
supply.
3. Remove the Nomex barrier from the power board side of the power supply.
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Replacement
1. Hold the Nomex barrier so that the edge
with the long cutout and 2 small notches
is on the left and the edge with 3 notches
is on the right.
Long cutout
2. There is a perforation across the top,
about 1inch down from the top edge. If
you are replacing the Nomex barrier with
a new one, you will need to fold it along
this perforation so that the top edge
bends away from you.
3. Position the barrier so that the edge with
the long cutout is toward the front (torch
end) of the power supply. Slide the
barrier into place with the bottom edge in
the same track the cover rests in. The
notches on each edge of the barrier
should align with the ribs on the inside of
the endcaps.
4. Being careful not to pinch any of the
wires, slide the cover back onto the
power supply. Make sure that the bottom
edges are in the tracks and that the slot
in the top of the cover lines up with the
tab on the front endcap. . Position the
handle over the holes in the top of the
cover, then use the 2 screws to secure
the cover.
5-8
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Track
Tab
Cover slot
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Page 5-9
Remove an endcap
Endcaps can be removed to replace them. Also some repairs are easier to make with an endcap
removed.
2. Remove the cover and the Nomex barrier.
3. Lay the power supply on its side on a workbench or hold it upside down. The raised feet on the
bottom of the unit have holes to provide access to the snaps that hold the endcaps in place.
Next to each foot is a raised rib.
Rear endcap
Rib
Front endcap
Rib
Snap
Snap
Retaining
screw
Retaining
screw
Snap
Snap
Rib
Rib
4. Remove the retaining screw from the bottom of the endcap.
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5. There are snaps on either side of each
endcap that hold the endcaps in place.
Insert needlenose pliers into the
opening for one of the snaps and use
the pliers to squeeze it together.
6. Place a flat-head screwdriver against
the raised rib next to the snap and
gently turn the screwdriver to push the
endcap away from the base.
7. Place another screwdriver or similar
object into the opening between the
endcap and the base to keep the first
corner of the endcap from returning to
its original position when you release
the other corner.
8. Repeat steps 5 and 6 on the other
corner of the endcap.
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Page 5-11
9. To replace the endcap, push it into the base to re-engage the snaps and then replace the
retaining screw.
10. Replace the Nomex barrier and slide the cover back onto the power supply.
11. Position the handle over the holes in the top of the cover, then use the 2 screws to secure the
cover.
12. Reconnect the electrical power and the gas supply.
Disconnect the torch lead
2. Remove the cover and remove the Nomex® barrier from in front of the power board.
3. Compress the hose fitting collar and pull the hose from the fitting to remove the gas hose from
the solenoid valve.
Front endcap
Solenoid valve
Hose fitting collar
White wire group
Red wire group
Gas hose
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4. Carefully tilt the front endcap away from the power supply. The orange, blue, and purple wires
from the torch lead are connected to the power board with a 3-pin connector at J12. Remove
the connector from the power supply by pulling it toward the front of the power supply.
J12
5. The white wire group and the red wire from the torch lead are secured to studs in the power
supply’s center panel. Use a 5/16” (8mm) nut driver to remove the nuts from the studs and
slide the ring terminals off the studs.
6. Unscrew the torch lead’s strain relief from the front of the power supply and then remove the
torch lead.
7. To reconnect the torch lead, route the wires and the gas supply line for the torch lead through
the hole in the front of the power supply.
8. Push the torch gas supply hose into the fitting on the bottom of the solenoid valve. The hose
goes in approximately .65” (16 mm).
9. Slide the ring terminal for the white wire group over the left stud (labeled “wht” on the center
panel). Slide the ring terminal for the red wire onto the stud on the right (labeled “red” on the
center panel). Tighten the nuts onto the studs.
10. Thread the orange, blue, and purple wire group over the center panel with the wires resting in
the notch in the panel. Tip the endcap away from the power supply and press the connector
into the slot on the power board.
11. Tighten the torch lead’s strain relief onto the power supply by screwing it into place and
reposition the endcap.
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12. Replace the Nomex barrier and slide the cover back onto the power supply. Position the
handle over the holes in the top of the cover, then use the 2 screws to secure the cover.
Replace the work lead
2. Remove the cover from the power supply and remove the Nomex barrier from in front of the
power board.
3. Remove the screw and washer from J22 on the powerboard (also labeled “work lead”) that
attaches the lead to the board. Set the screw and washer aside.
Front end cap
Work lead
Strain relief
Work lead connection
to power board (J22)
4. Either remove the front endcap or gently tilt it away from the power supply. From the inside of
the endcap, unscrew the nut that secures the strain relief to the endcap.
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5. The work lead may be knotted to adjust the length of the wire inside the power supply. If so,
untie the knot and then thread the work lead through the opening in the end cap.
6. Thread the connector end of the new work lead through the end cap and fit the strain relief
into the hole in the front endcap. Unscrew the strain relief to loosen it if you need to adjust the
amount of work lead on either side of it.
7. Slide the nut over the work lead connector. Gently tilt the end cap away from the power supply
and screw the nut onto the strain relief.
8. Attach the work lead to the power board at J22 using the screw and washer that you removed
earlier. The torque setting for this connection is 20 inch-pounds (1.4 kg cm)
9. Replace or realign the end cap.
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Replace the power cord (CSA)
power board.
3. Remove the rear endcap.
4. The power cord has a black wire and a white wire that connect to the power switch and a green
ground wire that connects to the heatsink.
Carefully pull the connector for the white wire away from the power switch to disconnect it. You
can use needlenose pliers or a straight screwdriver to ease it out, if necessary.
5. Remove the black wire the same way.
Single phase
N
White wire
L
Black wire
powermax30
Operator Manual
L
Black
N
White
PE
Green
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6. Remove the screw that holds the green wire to the heatsink. There is a notch in the
powerboard to provide easier access to the screw.
Ground wire screw
7. On the outside of the power supply loosen the strain relief retention nut so that the wires move
freely. If you are replacing the strain relief, unscrew the nut on the inside of the power supply
as well.
8. Pull the wires through the hole in the endcap to remove the old power cord.
9. If you have a new strain relief, slide it onto the new power cord and thread the wires for the
new power cord through the hole in the endcap. If the old strain relief is still in place, thread
the wires through the strain relief.
10. Slide the strain relief’s nut over the wires and screw it to the strain relief from the inside of the
endcap.
11. Press the connector for the black wire onto the pin on the upper left side of the power switch.
12. Press the connector for the white wire onto the pin on the upper right side of the power
switch.
13. Screw the green ground wire to the heatsink with a torque setting of 15 inch-pounds (17.28
kg cm).
14. Position the wires in the wire chase up the side of the endcap and out of the way of the power
board. Once the wires are in place, tighten the strain relief’s retention nut on the outside of the
endcap.
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15. Replace the endcap.
Replace the power cord (CE)
power board.
3. Remove the rear endcap.
4. The power cord has a brown wire and a blue wire that connect to the power switch and a
green and yellow ground wire that connects to the heatsink.
Carefully pull the connector for the blue wire away from the power switch to disconnect it. You
can use needlenose pliers or a straight screwdriver to ease it out, if necessary.
Single phase
N
Blue wire
L
Brown wire
powermax30
Operator Manual
L
Brown
N
Blue
PE
Green/yellow
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5. Remove the brown wire the same way.
6. Remove the screw that holds the green and yellow ground wire to the heatsink. There is a
notch in the powerboard to provide easier access to the screw.
Ground wire screw
7. On the outside of the power supply, loosen the strain relief retention nut so that the wires
move freely. If you are replacing the strain relief, unscrew the nut on the inside of the power
supply as well.
8. Remove the plug from the old power cord.
9. From the inside of the power supply, pull the wires through the strain relief and the hole in the
endcap to remove the old power cord.
10. Route the plug wires of the new power cord through the strain relief and then through the hole
in the endcap. Do not remove the tubular ferrite bead from the power switch end of brown and
blue wires.
11. If you are replacing the strain relief, slide the new one onto the new power cord. On the inside
of the endcap, screw the nut onto the strain relief.
12. Press the connector for the brown wire onto the pin on the upper left side of the power
switch.
13. Press the connector for the blue wire onto the pin on the upper right side of the power switch.
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14. Screw the green and yellow ground wire to the heatsink with a torque setting of
15 inch-pounds (17.28 kg cm).
15. Position the wires in the wire chase up the side of the endcap and out of the way of the power
board.
16. Line up the end of the power cord’s rubber casing with the inside edge of the strain relief.
Tighten the strain relief retention nut on the outside of the endcap.
17. Replace the endcap.
Replace the air filter element
2. Remove the cover from the power supply.
3. Remove the drain hose from the hole in the bottom of the power supply’s base.
4. Unscrew the nut that holds the air filter in the bracket. Tip the bottom of the air filter away from
the power supply.
5. Unscrew the filter bowl from the body and remove it.
Nut
Bracket
Filter bowl
Drain hose
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6. Unscrew the element from the filter body while being careful not to allow the element to rotate.
7. Screw the new element to the filter body.
8. Reattach the filter bowl.
9. Reposition the air filter assembly in the bracket and replace its retainer nut.
10. Reconnect the gas supply to check for leaks.
11. Slide the cover back onto the power supply. Position the handle over the holes in the top of
the cover, then use the 2 screws to secure the cover.
Replacement and accessory parts
The following sections list part numbers and quantities needed for common replacement parts for
the Powermax30.
Power cords and adapters
Part number
228142
229135
229132
229133
229134
228140
Description
Kit: Powermax30 CSA power cord and adapters
Powermax30 CSA power cord
Extension power cord subassembly: 120V/15A adapter
Kit: Powermax30 CE power cord
Quantity
1
1
1
1
1
1
Accessory parts
Part number
Description
127102
027668
127144
127170
127217
128647
Basic plasma cutting guide
Deluxe plasma cutting guide
Dust cover
Carrying case
Carry strap
Air filtration kit
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Page 5-21
T30v hand torch assembly
Item
Part number
088001*
228111
075714
002244
228110
058503
228109
228113
1
2
3
4
5
6
7
Description
T30v Hand Torch Assembly with 15 ft / 4.5 m Lead
Kit: Handle
Screws, #4 x 1/2 SLTD Torx PAN, S/B
Safety trigger and spring replacement
Kit: torch head repair
O-ring: Viton .626 x .070
Kit: cap sensor replacement
Kit: torch lead replacement, 15 ft / 4.5 m
Quantity
1
5
1
1
1
1
1
* The torch assembly also includes one set of the consumables listed below.
1
7
6
4
2
5
3
Consumables
Part number
220478
220479
220483
220480
220569
powermax30
Description
Electrode
Swirl ring
Retaining Cap
Nozzle
Deflector (optional)
Operator Manual
Quantity
1
1
1
1
1
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Page 5-22
Filter regulator
Item
Part
number
Description
1
011106
Air filter element
Qty.
1
1
Work clamp
Item
1
Part number
Description
Qty.
123868
Work cable with clamp, 15 ft / 4.6 m
1
1
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Page 5-23
Powermax30 labels
Part number
228097
228098
Description
Kit: Powermax30 labels, CE
Kit: Powermax30 labels, CSA
T30v CONSUMABLE PARTS
Pièces Consommables T30v
220569*
220483
220480 220479
*Optional
*En option
220478
Data plate
Plaque signalètique
PN 110583 Rev. A
110583
WARNING
AVERTISSEMENT
ou un incendie.
endommagés.
110261 ..........CE safety label
110584 ..........CSA safety label
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5-24

Plasma arc cutting system

Transcripción

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